Huhtamaki Flexible Packaging Germany GmbH & Co KG

Abstract: 

This interview with Radek Paruszewski, Huhtamaki’s Senior New Business Development Manager, explores Pharma 5.0’s convergence of patient safety, sustainability and technological innovation. He addresses monomaterial barriers, smart serialization, accessible designs, and ESG compliance, emphasizing cross-sector collaboration to deliver resilient, future-ready pharmaceutical packaging solutions protecting patients and the planet through 2030.

1. In your view, how is the pharmaceutical packaging industry redefining the balance between patient safety, sustainability, and brand differentiation in the Pharma 5.0 era?

Patient safety is the reason the pharmaceutical industry is so regulated. Pharma 5.0 is about finding the right balance between technology and humans. In my view, Pharma 5.0 should integrate new technologies with ethics, environmental sustainability, and human behaviour to deliver highly personalized, patient-centric healthcare. In my role at Huhtamaki, I am excited about the opportunity to bring my knowledge of sustainable packaging materials to an industry which is so focused on patient safety. This is not an overnight challenge, it will take time and serious effort, managing old and new regulations. However, with the challenge comes also the opportunity to build new solutions protecting both the patient and the planet. 

2. Child-resistant and senior-friendly packaging often present conflicting design priorities. What innovations are helping manufacturers achieve compliance without compromising patient usability?

This is truly a challenge that us Healthcare packaging engineers and developers thrive on. We have a broad arsenal of features and solutions to pull from. Cognitive barriers, which present multi-step opening procedures with visible and clear opening guidance, would hinder an impulsive child yet allow access to a more patient adult. Features that slow down the activity, requiring a precise, step-by-step behaviour, would allow increased accessibility to the target audience. An example of this is packaging that requires two-step sequential opening processes with press slide or lift turn actions. Taking a more holistic view of packaging, including secondary (folding boxes, wallet-packs) and primary (blister packs) perspectives helps in bringing solutions to the classic trade-off. 

3. Monomaterial packaging is gaining traction as a sustainability solution. What technical and regulatory barriers still prevent large-scale adoption in pharmaceutical applications?

Obviously mono-materials are preferred as a sustainable solution due to the circularity aspect of those materials. Within the pharmaceutical industry, where patient safety is of primary concern, other factors come into play. Firstly barrier levels – how to give the package the same oxygen and moisture barrier as a multilayer aluminium material without aluminium. Then how does the material run on the existing packaging equipment. Having different materials on the inside and outside of a package makes the operating window bigger. Getting the settings wrong can cause the package to have leakers or air pockets rendering the product obsolete. So, finding the right settings for a mono-material is more challenging still, and here collaboration between the material developers and machine manufacturers is fundamental.

4. How do you see pharmaceutical companies measuring the true environmental impact of flexible packaging beyond recyclability claims alone?

As for non-pharmaceutical companies, environmental impact of their flexible packaging choices has to be comparative against the existing solution. Going beyond recyclability; carbon-footprint, water consumption, use of primary energy are all elements that all play a part in true end-to-end lifecycle analysis. A rigid packaging solution may be more readily recyclable, but we have to calculate also the impact of energy needed for production and recycling. In the end, a flexible solution could have a more reduced total environmental impact.  What is essential in the context of pharmaceuticals is that the solution in no way comprises the product quality or patient safety. 

5. Anti-counterfeiting technologies are evolving rapidly. Which authentication approaches do you believe will become industry standards over the next five years?

This is difficult to estimate. Five years is a very short horizon in terms of the pharma industry. Existing technologies such serialization through Data Matrix codes seem to be making progress with producers, importers, hospitals, pharmacies, and wholesalers. Here a distinction between OTC and RX needs to be made. In RX the guarantee comes from the doctor who is prescribing the drug, whereas with OTC the consumer themselves may search for product verification, so extending DTCs to cover this functionality could be a real possibility.  

6. With increasing digitalisation in pharma manufacturing, how can smart packaging integrate with connected supply chains and real-time traceability systems?

I referred to Data Matrix codes and the serialization. Serialization has benefits, in which we may get more product-level data, lifecycle tracking and increasing supply chain transparency. However the solutions are not yet frictionless, there is work to be done with the initial program set up. I think it’s a general feeling that if serialization can become part of a larger digital ecosystem the whole industry will benefit. 

7. As pharmaceutical companies transition toward sustainable materials, how can they maintain barrier performance, stability, and shelf-life requirements for sensitive drug products?

One of the biggest challenges of the transition to sustainable packaging is to ensure the same barrier level towards moisture, oxygen and light. Mono materials based on PET, PP, PE or Paper are not on the same or similar level of some of the traditional packaging materials based on PVdC, PCTFE, aluminium or glass. The industry is striving to manage this by enhancing the barrier properties of those polymers and materials. For example, at Huhtamaki our OmniLock™ Ultra Paper brings high barrier performance to a paper without the need for a separate aluminium layer. 

In assessing the possible transition to sustainable materials, it is important to really understand the barrier needs of the product and tailor the solution to match the need. 

8. What role do AI, automation, and advanced inspection systems play in improving packaging quality assurance and reducing operational risks?

New technology is much more advanced in for example analysing products and testing for substances. The old technology barriers are being slowly moved away. I predict that in the future years we will see many improvements and advances in both quality assurance and operations. Some of the solutions already exists, as seen in Pharmap 2026 presentations.

9. From a packaging supplier’s perspective, how are pharmaceutical companies adapting procurement strategies in response to ESG targets and evolving EU regulations?

From a packaging supplier’s perspective, it seems that pharmaceutical companies are to some extent protected under the proposed EU regulations, however all companies must reach their ESG targets. Therefore, new packaging needs to be designed with those objectives in mind. It seems that the speed of development in OTC is much quicker than that of RX.  Fortunately for Huhtamaki, we operate also in the FMCG industry, which requires faster packaging solutions. So we feel well placed to come up with solutions as and when they are required. For instance, most of our toothpaste producers, who are in many cases known OTC drug producers, have already switched into recyclable, low carbon footprint tubes.

10. How important is collaboration between packaging manufacturers, CMOs/CDMOs, and pharmaceutical companies in accelerating next-generation packaging innovation?

To answer shortly, collaboration is very important. For many pharmaceutical producers the CMOs/CDMOs are a key channel with the industry. CMOs/CDMOs by the nature of their business have to be up to date with novelties. In many cases CMOs/CDMOs are the only operators having specific equipment. Often the special requests from the customers of CMOs/CDMOs land on packaging producers’ desks and this is how many new great developments start.

11. Looking at current geopolitical and supply chain disruptions, what packaging-related vulnerabilities should pharmaceutical manufacturers prioritize today?

I would say that the current unstable environment leads to two main issues. The first one is related to price increase of some of the polymers like PP or PE. The second one is the availability of oversee transport and cost of the transport in general. However, 105 years of experience has taught Huhtamaki that with enough planning and management, operating in any circumstances is possible. We stay calm, adapt and build contingencies. 

12. As sustainability regulations tighten across Europe, what strategic investments should pharmaceutical packaging companies make now to remain competitive and compliant through 2030?

Pick the right partner and invest together in developing future ready solutions today. That partner should have with first-hand knowledge and input of the regulations in process. They should have strong collaboration with machine manufacturers and suppliers of raw materials, to put theory into practice and make workable real-life solutions. And finally pick a partner who recognises the nuances of the pharmaceutical packaging industry and can tailor solutions to it.

On a related note, Radek recently shared his expertise as a featured speaker at PHARMAP 2026. An event supported by Media Partner Packaging and Labelling, it provided the stage for his insightful presentation on 'Next-Gen Pharmaceutical Packaging: Smart, Sustainable, and Secure.