Ecodesign in Action: API Emissions—Pharma’s Hidden Carbon Giant
"Roughly 25% of pharmaceutical manufacturing emissions come from the production of Active Pharmaceutical Ingredients (APIs), with most derived from fossil fuels, making API synthesis one of the most carbon-intensive stages in the drug lifecycle." (Source: API manufacturing: The cost of decarbonization | McKinsey)
To address this challenge, a leading global consumer healthcare company partnered with Evalueserve's IP and R&D practice to evaluate how its manufacturing processes could be redesigned for greater sustainability. The initiative aimed to:
- Decarbonize production to support net-zero targets,
- Reduce environmental impact indicators (e.g., land, water, and energy use), and
- Ensure alignment with evolving EU frameworks on sustainable and Green Chemistry manufacturing.
This case study examines how EcoDesign principles and Green Chemistry innovations were integrated to develop a strategic roadmap for transformation.
Diagnose - What's Blocking Sustainable Progress in API Manufacturing
Current manufacturing systems and complex supply chains pose significant challenges to the client's sustainability ambitions. Evalueserve's diagnostic phase focused on three key challenges:
High-Impact Emissions
Scope 3 emissions—performing detailed life cycle assessment (LCA) studies on all aspects of API synthesis at key supply chain sites is critical for identifying environmental hotspots in synthesis.
Groundwork for Regulatory Alignment
EU frameworks are reshaping expectations for environmental sustainability, with demands for compliance and future investment in Green Chemistry innovations and the sustainable manufacturing of APIs, requiring a shift in both mindset and methodology.
Innovation Gaps
Existing synthetic routes for APIs often lack the integration of sustainable technologies, limiting opportunities for decarbonization and resource efficiency.
💬 Key Question:
What innovations in the production of raw materials, solvents, catalysts, intermediates, and process technology are there that can be deployed to reduce environmental impact indicators?
This question guided the diagnostic process, helping identify where the most significant sustainability gains could be achieved across the production lifecycle.
Design Solution - Green Chemistry and EcoDesign in Action
The solution design focused on two transformative pillars:
EcoDesign thinking and Green Chemistry innovation.
Evalueserve conducted an in-depth assessment of synthetic API manufacturing routes and benchmarked the most promising alternatives, including bio-based and hydrogen-based technologies. The design phase was evaluated:
- Emerging API synthesis methods that demonstrate high sustainability potential,
- Renewable feedstocks and low-energy catalytic processes,
- Closed-loop solvent systems and
- Learnings from decarbonization strategies in non-pharma industries adapted to healthcare contexts.
💬 Key Question:
What are the "state of the art" API synthesis methods using sustainable technologies?
This question ensured that only advanced and cross-industry-validated technologies were shortlisted.
Deploy Solution - Translating Innovation into EcoDesign in Action
With a clear innovation roadmap in hand, Evalueserve moved swiftly to identify and prioritize actionable solutions. The deployment phase focused on three strategic actions:
Rapid Technology Screening
A fast-track evaluation of bio- and hydrogen-based technologies was conducted to identify those with the highest potential for environmental and operational impact.
Groundwork preparation
A technical and economic feasibility assessment will follow the client's evaluation of technology options, ensuring that the proposed solutions are scalable, cost-effective, and aligned with the client's production capabilities.
Real-World Validation
Green Chemistry principles and thinking were applied to real-world manufacturing contexts, ensuring that the theoretical benefits of multiple options were ranked into potential, practical, and measurable improvements.
💬 Key Question:
What are the key learnings for decarbonization in non-Pharma industries that apply to the client's company?
This question was central to identifying proven strategies that could be adapted and deployed with confidence.
Impact - Building a Roadmap for Sustainable Manufacturing Leadership
The project delivered a robust and well-defined roadmap for sustainability transformation. Key results included:
- A curated portfolio of bio- and hydrogen-based synthesis options,
- Cross-sector insights into technologies that reduce land, water, and energy use,
- A blueprint for embedding EcoDesign and Green Chemistry studies into ongoing R&D and manufacturing activities,
- A foundation for Scope 3 emissions reduction through more innovative supply chain interventions.
By systematically integrating sustainability assessments into manufacturing strategy, the company is now well-positioned to:
- Achieve its net-zero commitments,
- Stay ahead of regulatory compliance and
- Lead the industry in sustainable product development.
Interested in the practical steps behind this transformation? Visit our Environmental Sustainability Services page to dive deeper into the methods, success stories, and tools we use to turn net-zero ambitions into measurable results.
💡 Looking to build a similar roadmap?
Download our whitepaper, Enhancing Product Sustainability Through Life Cycle Assessment and Eco-Design, to discover how leading organizations are leveraging LCA and EcoDesign to drive innovation, compliance, and measurable environmental impact.
