The cold chain is a vital component of the modern pharmaceutical ecosystem, with its roots traced back to the early 20th century. It performs an essential function by ensuring the safe and efficient production, storage, and shipping of key drugs that need to be kept at a very low temperature. These include some influenza and hepatitis vaccines, some specialty pharmaceuticals such as chemotherapy agents and ophthalmic solutions, or hormone and enzyme replacement therapies.
Attention to cold chain operations became heightened during the COVID-19 pandemic. Although this spotlight affirmed the cold chain’s status as a lifesaver, it also resulted in increased attention on its green credentials. Indeed, many started to question just how sustainable the cold chain is, especially considering the significant energy and power needed to maintain such low temperatures.
Ensuring the pharmaceutical cold chain is sustainable involves various strategies, all of which need to work in unison to secure its overall success.
Sustainability issues
Most of the overriding reasons for the historical unsustainability of the cold chain stem from the fact that vast amounts of energy are needed to power it. Considerable resources are required to maintain stable temperatures throughout the entire supply chain. This includes refrigeration systems, freezers, and insulated containers, which will likely need to operate 24/7. Furthermore, certain drugs have ultra-low temperature requirements, such as some vaccines requiring storage at -80°C that demand even more powerful cooling systems, which consume significantly more energy than regular refrigeration.
In addition to the units needed in manufacturing, packaging, and storage units, when it comes to distribution, refrigerated transportation vehicles, including trucks, planes, and ships, use additional fuel and energy to power cooling units. These units run continuously, even when vehicles are not in motion, contributing to energy inefficiency. Furthermore, the international shipping of pharmaceutical products involves complex routes and long journeys, requiring sustained refrigeration, which increases fuel consumption.
Other factors contribute to high energy use too, factors that are possible to control with better organization. For example, poor route planning, uncoordinated shipments, or storage mismanagement can lead to longer transit times, which directly correlates to increased energy demands. An unoptimized supply chain requires extra cooling over extended periods, driving up energy consumption.
Energy efficiency
As we have seen, maintaining a low temperature across all aspects of the pharmaceutical cold supply chain involves energy usage – this is a fact, and there is no way around it. Therefore, it is key to use the energy needed as smartly as possible, and of course, rely on renewable energy sources where they are available.
We have already touched upon the issue of older equipment and antiquated systems. However, all equipment should be regularly reviewed, with companies continuously looking to the future to ensure they will be operating in the most efficient overall manner possible. This is especially true against the background of a much greater emphasis on the need for sustainability across all industries, not just pharma. Drugmakers should at least be actively planning now on how to harness green energy in the future. Even if the changes won’t happen overnight, they ought to be factoring in future equipment upgrades to ensure they are using the most energy-efficient refrigeration units and storage facilities.
The modern equipment available today – and certainly in the future – will almost always have much better insulation and energy use metrics than were available even a few years ago. A smart manufacturer will be regularly reviewing the options open to them and planning how they can be seamlessly incorporated in the future.
Where possible, renewable energy should be used to provide the power that cold stores rely upon, with solar or wind power becoming increasingly popular. The latest energy management systems can harness this renewable energy and optimize its usage even further by reducing wastage. Such systems comprise sophisticated tools and technologies designed to monitor, control, and optimize the performance of energy within buildings or facilities. They play a critical role in improving energy efficiency, reducing costs, and minimizing environmental impact.
Lower temperature requirements
It is important to note that in some cases, the medicines themselves are changing, which is positively impacting the amount of energy needed to maintain their efficacy. For example, innovation is taking place, meaning that some medicines, despite still needing to be kept very cold, do not require being kept as cold as they once did. This shift is largely influenced by the development of new formulations and improved cold chain management systems.
Insulin provides a good example. Traditionally requiring strict cold storage, newer formulations of insulin can now withstand higher temperatures for limited periods, reducing dependency on constant refrigeration. For example, some types of insulin can be kept at room temperature (up to 86°F) for up to 28 days once opened. This reduction in the thermostat temperature correlates, in many cases, with less energy being used to maintain the new, less cold, required temperature.
Sustainable packaging
The usage of sustainable packaging goes a long way to reducing the harmful environmental impact of the pharma cold chain. Sustainable packaging often involves using recyclable or biodegradable materials, which helps reduce the amount of waste generated. This is particularly important in the pharmaceutical industry, where packaging waste can be substantial. Eco-friendly packaging materials also typically require less energy to produce and recycle, reducing the overall carbon footprint, with lighter packaging going some way to reducing transportation emissions.
Furthermore, cold chain monitoring systems often rely on software that seamlessly, on a non-intrusive basis, is interoperable with existing enterprise IT solutions. This means that the carbon footprint continues to be controlled, as no extra servers or hardware is needed. The correct packaging solutions will also enhance levels of product integrity. Sustainable packaging solutions are designed to provide effective thermal insulation, ensuring that temperature-sensitive pharmaceuticals remain within the required temperature range during transit. This is crucial for maintaining the efficacy and safety of the medications.
Improved packaging designs can also offer better protection against physical damage and contamination, reducing the risk of spoilage and wasting the products contained within it. Sustainable packaging also aligns with global sustainability goals, such as the United Nations Sustainable Development Goals (SDGs). This contributes to broader efforts to combat climate change and promote sustainable practices. Ensuring that packaging materials are sustainable supports the long-term viability of the pharmaceutical supply chain, making it more resilient and adaptable to future challenges.
Optimized transport
A key component of the pharma cold chain is transportation. This could be anything from relatively localized transport from one town to another within the same country or sending a product halfway across the globe. Ensuring a transport network is fully optimized involves several strategies which all need to work together in order to guarantee sustainable efforts are maximized.
One crucial aspect is route optimization. Advanced route planning, using sophisticated logistics software, will plan the most efficient routes, considering factors such as traffic, weather conditions, and delivery windows, which will minimize travel time and fuel consumption. Furthermore, dynamic routing will allow the implementation of real-time route adjustments based on current traffic conditions and other unforeseen variables to avoid delays and ensure timely deliveries.
Once the routes have been sorted, the temperature control technology needs to be correct. Vehicles will need to be equipped with advanced refrigeration units that maintain precise temperature control throughout the journey. They will also need to be fitted with temperature-controlled containers that use battery-powered systems or passive containers with phase change materials (PCMs) or dry ice to maintain the required temperature range.
Compliance with regulatory standards is also essential. Ensuring that transport solutions comply with international standards such as Good Distribution Practice (GDP) and the World Health Organization (WHO) guidelines for the cold chain should be an integral part of all planning. Manufacturers should also look at their Standard Operating Procedures (SOPs), developing and adhering to these without fail for all aspects of cold chain transport, including loading and unloading procedures, handling protocols, and emergency response plans.
Sustainability solutions
There are a host of other methods to ensure the cold chain benefits from higher sustainability levels. These include much tighter coordination between the different suppliers and components of the supply chain, including suppliers, manufacturers, and distributors. This will help to ensure timings are tighter all around, minimizing the need for prolonged storage. It will also help to improve inventory management, which will reduce overstocking and the associated energy costs for storage.
It is also worth emphasizing that true end-to-end tracking, with just one point of contact on a single item basis, enhances overall efficiency – saving time and energy – and results in a much lower overall total cost of ownership.
More emphasis on training and awareness is also important. Educating employees on the importance of sustainability and training them on best practices for maintaining an efficient and eco-friendly cold chain will ensure the entire sector benefits from shared standards. Engaging with stakeholders will ensure sustainability goals are aligned and supported across the supply chain.
Innovation and investment in research and development is also a factor. Research into new technologies that can improve the efficiency and sustainability of cold chain processes will ensure the future remains as sustainable as possible.
Leveraging technology
The rise of modern systems has revolutionized the methods available for ensuring cold chain temperatures are kept at optimum levels. These systems leverage advanced technologies to provide real-time visibility, automated control, and proactive management, ultimately safeguarding product integrity and patient safety.
The use of Internet of Things (IoT) devices and sensors provides real-time monitoring of temperature conditions, ensuring that only the necessary cooling is applied. This is, of course, vital for conserving energy and ensuring that resources are not being used unnecessarily. Predictive analysis can furthermore anticipate and mitigate temperature excursions, reducing energy use by maintaining perfect conditions throughout the supply chain.
There are multiple benefits to be derived from systems such as these. They include improved product safety by ensuring that pharmaceuticals are stored and transported within the correct temperature range, enhanced traceability by providing end-to-end visibility, reducing the risk of temperature excursions and ensuring accountability, and operational efficiency through streamlining supply chain operations via automation, real-time monitoring, and proactive management. Cost savings are also achieved by reducing waste and spoilage of high-value products.
Looking ahead
The pharma cold chain is key to ensuring that patients across the globe can rely on the medications being produced, stored, and shipped to them in perfect conditions. However, as with all aspects of the pharma sector, it cannot escape criticism from those who are concerned it needs to work harder to up its sustainability credentials.
Let’s not forget, the cold chain is essential. All parts of the pharma supply chain need to work together to ensure its sustainability credentials are as strong as its life-saving credentials.
