Aptar Launches Bio-Based Nasal Spray Packaging Solution

Aptar Pharma has achieved a significant breakthrough in sustainable pharmaceutical packaging—its Freepod nasal spray pump is now mass-produced using mass balance bio-based resin. According to the company, this spray pump, used in Haleon’s Otrivin brand products, is Aptar’s first drug delivery device to utilize such materials and achieve global commercialization.

This innovative initiative marks a crucial step in reducing the use of fossil-based materials in primary packaging in the healthcare sector. For a long time, sustainability improvements in this field have faced numerous challenges.

Gael Touya, President of Aptar Pharma, stated: "At Aptar, sustainability is not only a responsibility but also a strategic advantage. The launch of Freepod Futurity demonstrates our commitment to developing solutions that respond to the growing consumer demand for more sustainable healthcare drug delivery technologies."

Reusable materials in pharmaceutical packaging

The Freepod spray pump used in Haleon's Otrivin nasal spray contains 52% bio-based materials certified by ISCC Plus. The company also mentioned that the accompanying bottle is produced using the mass balance method, with a bio-based content equivalent to 100%. Combined, the overall proportion of recycled materials in the entire nasal spray device reaches 60%.

This development responds to the growing industry demand for more sustainable packaging solutions in the healthcare sector, without compromising product integrity and performance.

Certified Sustainable Supply Chain

Aptar’s production facility in Mezzovico, Switzerland, has obtained ISCC Plus certification, ensuring full traceability of materials throughout the production process. The company stated that this certification covers all external suppliers, including injection molders, service partners, and warehouses, providing a fully certified supply chain guarantee for Freepod components.

Bio-based resins are derived from renewable raw materials such as biological waste and residual oils, and their production process adopts the mass balance approach certified by ISCC Plus.

Long-term cooperation yields fruitful results.

The sustainable development project stems from a 30-year collaboration between Haleon (formerly GSK Consumer Healthcare) and AptaPharma. The partnership has achieved several significant outcomes, among which the Otrivin Freepod was awarded the World Packaging Award in 2019 for its innovative and sustainable design.

The application of bio-based materials helps Haleon achieve its ambitious sustainability goals: reducing the use of virgin fossil-based plastics by 10% by 2025 compared to 2022 levels, and by one-third by 2030.

Looking ahead, both parties plan to extend their cooperation to Haleon's latest micro-droplet technology product — Otrivin nasal spray.

For the plastic industry, this commercialization case proves that bio-based materials can successfully transition from the conceptual stage to the global market and be applied in demanding fields such as pharmaceutical packaging. This may pave the way for similar innovations in other healthcare products.

Aptar Pharma is a subsidiary of AptarGroup Inc., headquartered in Crystal Lake, Illinois, USA, with over 13,000 employees in 20 countries. The company specializes in the design and manufacture of drug delivery, consumer product dispensing, and active material science solutions. It is particularly adept at packaging and drug delivery devices, developing dispensing solutions using advanced plastic processing technologies such as injection molding, blow molding, and precision assembly systems.

Haleon plc is a British multinational consumer healthcare company headquartered in Weybridge, United Kingdom. It was established on July 18, 2022, following the demerger of GlaxoSmithKline's consumer healthcare business.