The medical device industry has an important responsibility and opportunity to adopt sustainable practices. Medical devices improve patient health outcomes, but the manufacturing processes can have negative environmental impacts if not properly managed.
The industry must address plastic use, energy consumption, and waste generation. Regulatory pressures and consumer and market demands are driving medical device companies to implement greener operational models.
Injection molding is a critical manufacturing process used to produce a wide range of medical products, including components for diagnostic equipment, drug delivery devices, and medical implants. The process works by heating plastic material until it melts and injecting it into a mold cavity, where it cools and solidifies into the final part shape. Injection molding enables efficient mass production of complex and intricately shaped plastic parts with precision.
However, if not properly managed, it can also lead to significant material waste and energy usage. Thus, the medical industry has a key opportunity to implement sustainable injection molding through increased automation, process optimization, material and energy efficiency standards, and recycling practices. Adopting green injection molding principles is an impactful way for medical device manufacturers to improve their triple bottom line.
Sustainable Material Selection
Medical device manufacturers can choose more eco-friendly materials like polylactic acid (PLA) made from plant starches rather than traditional petroleum-based plastics. PLA and other biopolymers break down easier after disposal to reduce environmental accumulation. Using renewable feedstocks supports the circular economy. However, testing is critical to ensure comparable device functionality and biocompatibility.
Recycled and recyclable materials
Incorporating post-industrial and post-consumer recycled resins cuts down on virgin material demands. Designing parts that are easily recyclable after end-of-life also promotes recycling. Recycled materials must meet stringent medical grade specifications throughout the manufacturing process and lifecycle. Process validation and quality checks are key to safely using recycled plastics.
Material optimization for reduced waste
Careful analysis of part geometries and production runs can identify opportunities to use less raw material without compromising quality. This includes determining ideal wall stock thickness, minimizing parts size, consolidating mold cavities, and analyzing runner systems. Automation and process simulations can optimize material requirements and predict and reduce manufacturing defects. Together, these material efficiency efforts translate to lowered costs and environmental footprints.
Energy-Efficient Injection Molding Processes
Switching to all-electric injection molding systems powered by digital servo motors can yield significant energy savings compared to less efficient hydraulic machines. Maintenance costs are also lower. Precision control enables consistency and high part quality. While the upfront capital investment may be higher, the total operating costs are lower.
Servo-hydraulic systems
Servo-driven hydraulic systems provide better energy efficiency than standard hydraulic machines for facilities that cannot completely upgrade equipment. These systems use electric servos to power the hydraulic pump and injection, saving power between cycles. They also enable more precise control and faster cycle times.
Optimized process parameters for energy savings
A holistic analysis of machine settings can maximize energy conservation in the injection molding process. This includes optimizing clamp force, minimizing cooling times, adjusting packing pressure, and finding the lowest acceptable mold and melt temperatures. Automating parameter control with machine learning and AI can continuously optimize for efficiency. Production scheduling also impacts energy use.
Waste Reduction Strategies
Incorporating design for manufacturability (DFM) guidelines during the product development phase helps minimize material use, machining, and opportunities for defects. DFM also promotes standardization and design reuse rather than reinventing components. This proactive approach reduces material expenses and waste while improving process efficiency.
Runner and sprue optimization
The feed system that delivers plastic into mold cavities leaves behind scrap plastic called runners or sprues after molding. Optimizing runner dimensions and using cold runners or insulated hot runners improves material yield. Diverting runners back into the process also increases reuse.
Hot runner systems
Hot runner molds with integrated heating eliminate the need for runners and sprues altogether. The plastic stays molten within the system instead of solidifying after each shot. This technology provides near 100% yield for straight plastic parts and minimizes cycle times. It does require higher upfront capital and maintenance costs.
Recycling and reusing scrap material
Grinding down scrap plastic from runners, sprues, defective parts, and trimmings to reuse internally or sell to recyclers reduces material inputs. Automated sorting and material handling streamline scrap processing. Consistency in resin selection and separation processes ensures high reuse quality.
Sustainable Facility Operations
Using on-site solar, wind, or other renewable energy helps reduce fossil fuel consumption from electricity usage in medical device manufacturing facilities. Renewable energy investments can repay over longer terms and hedge against utility price variability. Facilities can also purchase renewable energy credits or carbon offsets.
Energy-efficient lighting and HVAC systems
Replacing older lighting fixtures, HVAC units, pumps, compressors, and other equipment with newer, high-efficiency models greatly reduces a production facility’s day-to-day energy requirements. Smart building automation further optimizes energy use.
Water conservation and recycling
Installing low-flow faucets and conducting regular leak checks minimizes water waste. Collecting, treating, and reusing process water multiple times before discharge reduces the consumption of cooling systems, part washers, and equipment cleaning. Rainwater capture also supplements use.
Supply Chain Sustainability
Medical device companies should select and collaborate with raw material and component suppliers who share their sustainability commitments. This includes working with certified green and socially responsible partners and small and local businesses to reduce transportation impacts. Joint process improvements further amplify positive impacts.
Sustainable packaging solutions
Optimizing packaging size, using recyclable and recycled packaging materials, and reducing protective filler usage cuts down on discard volumes. Plastic replacement with cost-effective and biodegradable solutions like molded pulp further improves the supply chain eco-profile while maintaining product protection.
Optimized logistics and transportation
Analyzing transportation networks, modes, and packaging efficiency allows companies to minimize mileage and carbon emissions from product logistics. This may involve consolidation, switching to fuels with lower emission intensities, or reducing the number of trips. Companies can also offset remaining transportation emissions through certified climate programs.
Regulatory Compliance and Certifications
ISO 14001 Environmental Management System
Gaining ISO 14001 certification requires companies to implement a comprehensive environmental management system that drives continuous improvement around resource conservation, waste minimization, regulatory compliance, and supply chain impacts. The international standard ensures systematic progress.
LEED certification for facilities
Leadership in Energy and Environmental Design (LEED) provides a framework for designing, building, and operating green facilities focused on metrics like energy and water savings, reduced waste, lowered emissions, and indoor environmental quality. Medical device manufacturers can have their production plants and offices LEED-certified.
Compliance with RoHS and REACH regulations
Medical device makers must meet restrictions on hazardous substances in electrical equipment and electronics per RoHS regulations and properly register, evaluate, and communicate chemical ingredient usage under REACH requirements. Proactive compliance avoids market access issues.
By integrating the product lifecycle and supply chain, medical injection molding facilities can drive quantifiable results in lower emissions, energy, and water usage, improved material yields, and reduced waste. The industry must commit to real transformation towards more ecologically and socially conscious manufacturing models.
Take Action Towards Sustainable Medical Device Injection Molding!
At KS Plastic, we are committed to revolutionizing the medical device manufacturing industry through sustainable practices. Join us in driving sustainable change in the medical device injection molding industry. Work with suppliers who share our sustainability commitments, choose sustainable packaging solutions, and optimize logistics for lower carbon emissions. Together, we can create a greener, more responsible future. Visit KS Plastic to learn more and start making a positive impact today!