According to the United Nations, by 2050, two-thirds of the world’s population will be affected by the phenomenon of water stress linked on the one hand to increased demand for water, and on the other to reduced freshwater availability due to climate change, demographic growth, urbanization, and over-exploitation of both underground and surface water resources. 

This alarming situation reveals the need for all industries, including the pharmaceutical sector, to adopt sustainable water management practices. 

In this article, we will be sharing an average map of water consumption in the pharmaceutical industry, which will highlight the most high-consumption processes and will explore the sometimes-simple solutions to reduce water impact, ranging from lower consumption to reuse and recycling. 

1. Mapping of water consumption along the entire value chain

Water consumption in the pharmaceutical industry varies considerably depending on the processes involved and stages of production. Detailed mapping of this consumption is therefore essential to identify the most water-hungry points and target the optimization efforts to be deployed. 

Considering the entire drug manufacturing process and according to several studies, the rough figures in terms of water consumption are as follows: 

Figure 2. Breakdown of water consumption for manufacturing of sterile drugs 

• Manufacturing of active ingredients (25 to 35%)

Chemical synthesis consumes the most water. Consumption is more moderate in the case of a fermentation process, where it is mainly linked to preparing the growth medium. And plant extraction? This varies depending on the extraction process. 

• Drug formulation (5-30%)

Water consumption for drug formulation varies and depends on the dosage form and process implemented. With solid forms (tablets, capsules), consumption is moderate. Water is used for mixing and granulation (approx. 5 to 10%). 

Semi-solid forms (gels, creams) consume little water in proportion.
And water consumption when manufacturing sterile products such as injections, ophthalmic solutions, and products for infusion is more intense and can even exceed 30%. 

• Cleaning in place (CIP) and sterilization (15-20%)

CIP requires a significant quantity of water for cleaning equipment and production zones. Quality must also be tailored to use (purified water / water for injection). The heat sterilization process also has an impact on clean steam production (5 to 10%). 

And finally, some sterile drugs need to be freeze-dried to improve their stability. This process requires water for both steam production and cooling. 

• Utilities (15-20%)

The main sources of consumption are equipment and process cooling systems, as well as boilers that turn water into the steam used in heating, sterilization, and freeze-drying processes, as applicable. 

2. Special case. Manufacturing of sterile drugs

Manufacturing of sterile drugs must meet strict contamination risk control requirements, and involves stages requiring significant quantities of water. 

Water consumption, other than in the actual process, is mainly due to intensive cleaning of equipment and production zones vital to controlling contamination. 

Water production (mainly WFI) and utilities necessary for cooling and steam production are also significant. 

The graph (Figure 2) gives an idea of the breakdown of this water consumption. 

3. Solutions to reduce water impact

To tackle water consumption challenges, the pharmaceutical industry implements various solutions ranging from lower consumption in the first place to putting in place localized recycling and reuse loops. 

Based on water consumption mapping, it is smart to implement solutions to reduce consumption at the source in advance. 

Concrete practices can meet this need such as: 

• Optimization of cleaning in place (CIP) processes

Use of optimized cleaning techniques, such as spray cleaning or circulation cleaning, can considerably reduce water consumption while also maintaining high cleaning efficiency. Despite requiring regulatory, documentary and validation efforts, reassessment of existing recipes can prove advantageous. 

• Optimization of purified water and WFI production processes

Use of high-efficiency water purification technologies, such as multi-stage reverse osmosis and electrodeionization + UF, combined with a concentrate recovery and treatment system, minimizes water discharges and significantly reduces overall water consumption. 

Smart scaling of facilities and disinfection method and frequency can also have a non-negligible impact on non-essential water discharges. 

• Improvement of cooling system efficiency

Adoption of closed-circuit cooling systems, high-efficiency cooling towers, and waste heat recovery systems contributes to reducing cooling water consumption. 

Furthermore, the pharmaceutical industry is actively exploring recovery and reuse solutions to reduce demand for cool water. 

As regulatory requirements restrict the use of retreated water in processes, examples of reuse of wastewater mainly target grey utility applications such as: 

• Cooling water

Retreated water can be used to supply cooling systems, such as cooling towers or heat exchangers, reducing cool water consumption accordingly. 

• Boiler water

After appropriate treatment, water can be used as boiler feed water, producing grey steam for heating processes. 

• Cleaning water

Treated wastewater can be used for non-GMP cleaning of non-critical equipment, production zones, and surfaces. 

• Irrigation water

In some cases, retreated water can be used for irrigation of green spaces or non-food crops, contributing to sustainable water resource management. 

Furthermore, collaboration with stakeholders for responsible water management is essential to provide an effective and sustainable response. For example, the following initiatives should be considered: 

• Partnerships with water suppliers and local authorities to sustainably manage water resources and reduce environmental impacts,
• Raising awareness and training personnel about good water management practices and waste reduction,
• Commitment to local communities to promote responsible water use and protect shared water resources.

Finally, integration of water footprint assessment into decision-making processes is a responsible solution. Indeed, calculating the water footprint of products and manufacturing processes enables identification of critical control points and opportunities for improvement. 

The aim of setting reduction goals and tracking progress made via sustainable development programs is to encourage any initiatives and quantify their impacts. Taking account of water footprint in the design of new products and processes enables the most sustainable options to be prioritized. 

4. Conclusion

In conclusion, sustainable water management is a crucial issue for the pharmaceutical industry, requiring a holistic approach and concerted efforts. 

By mapping water consumption, identifying the most high-consumption processes, particularly in manufacturing sterile drugs, and implementing appropriate solutions ranging from lower consumption to reuse, the pharmaceutical industry can considerably reduce its impact on water resources. 

Although challenges remain, such as investment costs and regulatory requirements that currently restrict recycling of water in critical operations, the environmental, economic, and social benefits of sustainable water management are undeniable. 

Responsible water management will contribute to not only environmental sustainability, but also the pharmaceutical industry’s long-term resilience and competitiveness, in a world where water scarcity is becoming a major concern.