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Accelerating digital transformation in pharmaceutical manufacturing
and compliance as well as delivering greater patient engagement?
The good news is that solutions to these challenges are not only accessible, proven and commercially viable, but can also be rapidly adopted during routine line revalidation to minimise disruption. Better yet, these upgrades deliver measurable return on investment – often within the industry’s two-year target – making digital connected packaging not just a compliance or sustainability win, but a strategic business decision.
R
ising regulatory demands, sustainability targets and operational inefficiencies create a complex, high-stakes environment for pharmaceutical manufacturers. While these challenges span the entire manufacturing landscape, certain legacy processes – such as print and packaging – often serve as visible pressure points.
Tackling these areas can offer quick, measurable improvements in compliance, traceability and agility - without compromising patient safety. For instance, packaging processes, often considered a small element of the supply chain, go unnoticed as a source of inefficiency and risk. By applying a continuous improvement mindset, manufacturers can unlock measurable gains at every stage of production. From reducing waste and improving line efficiency to enhancing product integrity and accelerating digital transformation, this article explores how digital pharma packaging printing can become a strategic driver for change - starting with recognising the opportunity. Ian Chapman, strategic manager - digital coding, Domino, discusses the role of digitalisation in pharma packaging printing, and the value of a trusted partner to deliver more - more agility, more sustainability and more traceability.
UNLOCKING EFFICIENCY: THE MISSED OPPORTUNITY IN PHARMACEUTICAL PACKAGING
Digitalisation has become a core objective for pharmaceutical manufacturers over the past decade. Yet the widespread use of legacy print and packaging processes continues to limit opportunities for packaging to support reduced costs, improved efficiency and respond to demands for innovation. Many pharmaceutical manufacturers still rely on older, standalone TIJ and TTO systems, technologies that, while once industry standard, now limit opportunities for automation, data integration and traceability. In contrast, modern connected TIJ and TTO solutions offer cloud-enabled capabilities that align with digital-first manufacturing goals. Digital printing can eliminate the need to stock hundreds of pre-printed foil variants, reduce reliance on manual labelling, enable real-time customisation, and support the introduction of smart 2D codes to unlock traceability, patient engagement and compliance in one step.
This slow pace of digital adoption is not only inefficient; it hinders vital innovation. How can pharma manufacturers achieve the small batch sizes and late-stage customisation required for agility and responsiveness to different regulatory requirements globally? What is the roadmap for embedding smart 2D codes to improve product traceability
HOW DIGITAL PRINTING REDUCES WASTE AND BOOSTS LINE PERFORMANCE Digital printing eliminates the inefficiencies associated with the use of multiple pre- printed foils. Many manufacturers overorder between 15 per cent and 20 per cent of pre-printed stationery for each product line, resulting in significant waste – unused pre- printed foil often sits in a warehouse for months, even years, incurring unnecessary costs and undermining sustainability goals. This inefficiency is particularly problematic for initiatives such as the NHS in the UK, which is pursuing the ambition to become the world’s first Net Zero National Health Service. Digital printing helps reduce pharma packaging waste, storage requirements, and insurance costs (typically related to the volume of flammable product stored), while also avoiding the associated costs of destroying or recycling unused foil.
Digital technologies also play a vital role in reducing the risk of mislabelled products and rejected batches due to identification mistakes or printing errors. A single mislabelled product or unreadable code can trigger batch recalls, regulatory scrutiny and reputational damage. Inline digital printing, combined with automated inspection, helps to improve accuracy, minimise downtime and protect patient safety.
DRIVING SUSTAINABILITY THROUGH SMARTER PACKAGING CHOICES Reducing waste is also a key factor in the industry’s drive to improve its environmental credentials. Rationalising pre-printed foil by adopting agile digital printing technology delivers immediate sustainability gains. One manufacturer was able to rationalise
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November 2025
www.convertermag.com
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