Self-Contained Pharmaceutical Container Recycling System
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Solution Overview
Problem
The recycling of pharmaceutical containers is hindered by contamination issues and regulatory challenges due to the mixing of different plastic grades and additives, which complicates the recycling process and results in inadequate processing of used containers into new pharmaceutical-grade materials.
Innovation Solution
A self-contained recycling system that isolates pharmaceutical containers from other plastics, converts used containers into ground material, and reforms them into new unused containers using virgin or recycled resin, ensuring compliance with FDA and USP regulations, thereby maintaining a closed loop recycling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional recycling processes are used to recycle pharmaceutical containers, then recycling volume increases, but contamination issues and regulatory compliance deteriorate due to mixing different plastic grades and additives
Solution Approach 1:
The patent segments the recycling process into separate streams for different plastic grades and resin families. Collection bins are organized by plastic type (HDPE, PP, PET, etc.), and recycling facilities process each grade separately to prevent contamination. This segmentation maintains regulatory compliance while enabling large-scale recycling of pharmaceutical containers.
Solution Approach 2:
The patent extracts and removes contaminants from the recycling stream, including residual pharmaceuticals, labels, adhesives, and non-plastic components. Advanced cleaning and sorting processes isolate pure plastic materials from contaminated mixes, ensuring the recycled material meets pharmaceutical-grade requirements while processing large volumes.
2Quantity of substance
If pharmaceutical containers are collected and recycled through conventional processes, then recycling coverage increases, but manufacturing precision deteriorates due to loss of grade-specific additives and properties
Solution Approach 1:
The patent implements segmentation by maintaining separate recycling streams for each plastic grade and resin family. HDPE containers are processed separately from PP and PET containers, preserving the unique additive packages and material properties of each grade. This enables the recycled material to retain the manufacturing precision required for specific applications.
Solution Approach 2:
The patent applies parameter changes by controlling the chemical and physical properties of recycled materials through targeted processing. By adjusting processing parameters and selectively retaining or removing specific additives during recycling, the system preserves the functional properties needed for manufacturing new pharmaceutical containers while processing high volumes.
3Productivity
If used pharmaceutical containers are processed through conventional recycling facilities, then recycling throughput increases, but product quality deteriorates due to inadequate processing and contamination
Solution Approach 1:
The patent applies preliminary action by implementing pre-sorting and pre-cleaning of pharmaceutical containers before they enter the main recycling process. Containers are sorted by plastic type at collection points and pre-washed to remove gross contaminants, which enables high-throughput processing while maintaining product quality through reduced contamination levels.
Solution Approach 2:
The patent uses intermediary processing steps between collection and final recycling, including specialized cleaning facilities, sorting centers, and quality control checkpoints. These intermediary stages act as buffers that maintain product quality while enabling high-volume throughput by processing containers in controlled sequences rather than all at once.
Data Source
AI summary
Disclosed herein is a system and method of recycling of a pharmaceutical container system, which can include the container and closure for the container. The disclosure teaches a self-contained recycling system wherein the pharmaceutical containers that are made for consumer use are returned for processing and remanufacturing as new unused pharmaceutical containers to facilitate the ease of recycling of the same and the future use as unused pharmaceutical containers and viable consumer products.