Sustainable Green Polymer Production for Pharmaceutical Manufacturing: A Review of Environmental and Economic Impacts

Polymers are fundamental components of modern pharmaceutical manufacturing, serving critical roles as excipients, binders, coatings, and matrices for controlled drug delivery systems. However, the conventional production of pharmaceutical polymers relies heavily on petrochemical feedstocks, energy-intensive processes, and hazardous solvents, leading to significant environmental and economic burdens. In recent years, increasing regulatory pressure, environmental awareness, and sustainability goals have driven the pharmaceutical industry toward greener manufacturing strategies. This review critically examines sustainable green polymer production for pharmaceutical applications, with a focus on both environmental and economic impacts. The review discusses the role of polymers in pharmaceutical manufacturing, outlines the limitations of conventional polymer synthesis, and highlights the relevance of green chemistry principles in addressing these challenges. Key green polymer synthesis techniques, including biopolymer production, enzymatic polymerization, microwave-assisted synthesis, supercritical CO2 processing, and the use of ionic liquids and deep eutectic solvents, are systematically evaluated. Additionally, life-cycle assessment (LCA) approaches are explored to assess the environmental performance of green polymer processes in comparison with traditional methods. Beyond environmental sustainability, this review emphasizes the importance of pharmacoeconomic evaluation in determining the feasibility of adopting green polymers at an industrial scale. Cost–benefit analyses, manufacturing cost comparisons, long-term economic advantages, and health–economic outcomes are discussed in the context of pharmaceutical supply chains. Regulatory perspectives, industrial implementation challenges, and future directions are also addressed. Overall, this review highlights sustainable polymer innovation as a critical pathway toward environmentally responsible, economically viable, and future-ready pharmaceutical manufacturing.