As pharmaceutical companies look for ways to reduce the environmental impact of their packaging, many focus on complex system-wide changes. But in ready-to-use (RTU) packaging for syringes and vials, one component stands out as a practical, low-disruption opportunity: the tub.

That opportunity is the foundation of EnviroTEQ™, TEQ’s new portfolio of thermoformed PET packaging solutions designed to replace traditional polystyrene components.

What makes the RTU tub a focus for sustainability?

In an RTU packaging system, not every component can be easily redesigned.

The Tyvek® lid serves as the sterile barrier. Syringes and vials are product-contact components that are included in regulatory filings. Nests are tightly integrated with container geometry and filling-line requirements.

The tub is different.

Its job is to protect, transport, stack, and present containers for automated processing. While it must meet demanding performance requirements, it does not directly contact the drug product or function as the sterile barrier. As a result, changing the tub material can often be accomplished without triggering the extensive validation activities associated with other packaging components.

That makes it one of the most accessible ways to improve sustainability within the RTU system.

Why Replace Polystyrene?

For decades, injection-molded polystyrene has been the standard material for RTU tubs. While technically recyclable, polystyrene is rarely recovered at scale and faces growing challenges across recycling streams.

PET offers a compelling alternative.

It provides the clarity, rigidity, and dimensional stability required for pharmaceutical packaging while benefiting from a more established recycling infrastructure. Recycled PET (rPET) is also commercially available today, giving companies access to lower-carbon material options without sacrificing performance.

Measurable Carbon Reduction

TEQ conducted a first-pass lifecycle assessment comparing a thermoformed PET tub against a conventional injection-molded polystyrene tub.

The results showed:

• Approximately 20% lower embodied carbon using PET
• Approximately 32% lower embodied carbon using recycled PET (rPET)
• Roughly 253 metric tons of CO₂ equivalent avoided for every one million tubs converted from polystyrene to rPET

Most of this reduction comes directly from the resin choice itself, making material selection one of the most impactful sustainability decisions available to packaging teams today.

Building a Better Path Forward

No single material makes packaging circular on its own. Collection, sorting, and recovery systems still matter.

However, material choices can either preserve future sustainability pathways or limit them. Moving from polystyrene to PET creates opportunities that are difficult to achieve with legacy materials while delivering meaningful carbon reductions today.

With EnviroTEQ™, TEQ is helping pharmaceutical manufacturers take a practical step toward their sustainability goals without compromising the performance requirements of sterile packaging.

See how quickly conversion with TEQ is possible. Contact us and begin the technical conversation.

Sources

• TEQ® internal lifecycle assessment, EcoImpact Compass, 2026.

Lifecycle assessment note: Based on TEQ’s internal analysis comparing tub materials and manufacturing processes. Results include raw material production (resin), packaging manufacturing, and end-of-life assumptions. Sterilization, transportation, filling operations, and downstream distribution were not included in the assessment boundary.