Rise of Single-Use Technology - A Sustainability Paradox
Since the introduction of single-use technology over 25 years ago, disposable plastics have become ubiquitous not only in pharmaceutical manufacturing but throughout the global consumer market. From shopping bags to coffee cups, our society increasingly operates within a plastic-wrapped paradigm. As Environmental, Social, and Governance (ESG) legislation evolves worldwide, pharmaceutical companies face critical questions about the sustainability and future viability of single-use technologies.
The pharmaceutical industry currently navigates three competing pressures when considering single-use technology implementation.
First, there are substantial operational efficiency gains. Adopting single-use technology eliminates Clean-in-Place (CIP) and Steam-in-Place (SIP) cycles that traditional stainless steel equipment requires. Consumables are simply disposed of after production, external equipment surfaces are sanitised, and new consumables are installed. This streamlined approach can reduce changeover time between manufacturing campaigns by two to three weeks, enabling additional production cycles annually and significantly increasing throughput capacity.
Supply chain vulnerabilities present the second major challenge. Since the COVID-19 pandemic, the market has experienced persistent increases in lead times for single-use consumables, often extending to 52 weeks, compounded by global shortages in plastic materials and specialised tubing. These constraints have driven many companies to seek alternative sourcing strategies, including partnering with local suppliers who provide generic consumables compatible with multiple equipment types, such as standardised tubing sets or mixer bags.
The third pressure comes from sustainability imperatives. As suppliers pursue net-zero emissions targets, end-users are absorbing rising consumable prices that directly impact profitability. Simultaneously, manufacturers face substantial challenges in waste management for single-use materials, including the complex separation of different plastic types and the proper handling of packaging materials like cardboard and polystyrene. Whilst opportunities exist for landfill diversion through recycling, options remain limited in many regions, including Australia.
Despite these challenges, market forecasts reveal a striking paradox. The global single-use bioprocessing industry, valued at USD 26.65 billion in 2024, is projected to reach USD 112.2 billion by 2034, an extraordinary growth trajectory driven by increasing product demand and intensive R&D investments. These investments focus on both material advancements and expansion of the global biologics portfolio. This projected growth will inevitably create tension with sustainability goals for pharmaceutical companies worldwide. The resolution likely lies in collaborative innovation between suppliers and end-users to develop comprehensive end-of-life management solutions for single-use consumables, whilst simultaneously advancing waste-to-energy technologies and establishing more robust recycling programmes.
The pharmaceutical industry stands at a crossroads between operational efficiency and environmental responsibility. While single-use technologies offer compelling advantages in manufacturing flexibility and throughput, their environmental footprint presents significant challenges to sustainability commitments. Success will depend on developing innovative approaches that capture the benefits of single-use systems while minimising their environmental impact through advanced materials, recycling technologies, and circular economy principles.