Single-Use Bioprocessing:
Steps Toward a More Sustainable Future

The Rise of Single-Use Technology in Modern Biopharma

Single-use technologies (SUTs) have transformed modern biopharmaceutical manufacturing. By replacing traditional stainless steel systems with disposable components, SUTs have delivered faster changeovers, reduced the risk of cross-contamination, and lowered capital expenditure. They played a pivotal role during the COVID-19 pandemic, where agility and rapid scaling were essential.

While these single-use systems provide clear operational and economic benefits, their growing adoption raises important environmental questions. With the global biopharma industry already under pressure to meet sustainability targets, the way it manages the lifecycle of single-use plastics is now under intense scrutiny.

The Sustainability Trade-Off: From Production Efficiency to Plastic Waste

SUTs have become commonplace in biopharma for a multitude of reasons. Beyond reducing contamination risks, the lack of a requirement for high-temperature cleaning translates into major energy and water savings. This has enabled facilities to reduce resource consumption while maintaining consistent product quality.

The trade-off, however, is the significant volume of waste generated. Each bioreactor bag, filter, tube, or connector used in production becomes regulated plastic waste. This material is often classified as biomedical waste, which in most cases is autoclaved before being sent for incineration or to landfill, processes that carry a high energy cost and significant carbon emissions.

Why a Full Lifecycle Approach is Essential

Addressing this challenge requires a full lifecycle approach. It is no longer enough for companies to optimise efficiency at the point of use; they must also consider the entire journey of the product.

Key Stages of the SUT Lifecycle

• Material Sourcing: What polymers are chosen, and are there more sustainable alternatives available?
• Manufacturing Impacts: What are the energy, emissions, and transport costs involved in producing SUTs?
• Use Phase: How do the water and energy savings compare with traditional stainless steel systems?
• End-of-Life: How is the waste treatment managed, and can valuable materials be recovered?

Lifecycle analysis provides the transparency needed to identify environmental hotspots and make informed choices. As regulators and investors increasingly focus on Environmental, Social, and Governance (ESG) performance, companies that demonstrate robust lifecycle accountability will gain a significant competitive edge.

How the Industry is Driving Change

Encouraging initiatives are already emerging across the sector to tackle the challenge of biohazardous waste.

• Partnership Programmes: Major pharmaceutical companies are piloting schemes for waste recycling, aiming to recover valuable polymers instead of relying solely on incineration. An effective clinical waste collection system is fundamental to the success of these programmes.
• Embracing Innovation: Suppliers are exploring new polymers with lower carbon footprints and exploring technologies like GENERATIONS to enable more sustainable end-of-life opportunities, including biohazardous waste recycling. This innovation is often led by specialist biohazardous waste treatment companies.
• Standardised Frameworks: Industry groups such as the ISPE (International Society for Pharmaceutical Engineers) are developing guidance on sustainability metrics, helping companies benchmark performance and improve. Many of these standards are shaped by insights from regulated waste treatment companies.
• Collaborative Models: Conferences and working groups dedicated to single-use sustainability are accelerating knowledge sharing across the sector.

While progress is uneven, the direction of travel is clear: single-use bioprocessing must evolve to balance its operational benefits with genuine environmental responsibility.