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Sustainability by Design in API Manufacturing

Download Case Studies Showing 85% Reduction in the Carbon Footprint

Download the White Paper

A Practical Blueprint for Sustainable Small Molecule Manufacturing

The pharmaceutical industry accounts for 4–5% of global greenhouse gas emissions. API manufacturing alone contributes around 25% of that footprint. This white paper outlines Merck’s real-world process improvements using green chemistry principles, smart synthesis design, and advanced analytical frameworks such as DOZN™ and GreenSpeed.

Inside This White Paper:

  • Case studies showing PMI reduction from 4,793.3 to 845.0 and from 12,339.5 to 181.0.
  • How continuous flow manufacturing reduced carbon footprint by 20% and 85% in different processes.
  • DOZN™ Quantitative Green Chemistry Evaluator and GreenSpeed platforms.
  • The 12 Principles of Green Chemistry framework and application.
  • Process redesign approaches, including synthetic route optimization and column elimination.
  • Yield improvements from 39% to 66% and from 65% to 75%.

25%

API Manufacturing’s Share of Pharma Emissions

70%

New Drugs are Small Molecules (2013-2023)

12

Principles of Green Chemistry Applied


Proven Results from Real Projects

These case studies demonstrate the dramatic improvements possible through strategic process redesign and green chemistry implementation.

Process 1

Multi-Step Synthesis Redesign (Original vs. Redesigned Route)

PMI Reduction                                                          4,793 → 845 

Overall Yield                                                                   39% → 66%

Solvent Intensity                                                       83.9% reduction

Product Purity                                                        >99.5% maintained

Process 2

Column-Free Purification Strategy (Original vs. Redesigned Route)

PMI Improvement                                                     12,339 → 181
 
Process Steps                                                            3 → 2 steps
 
Columns Eliminated                                                6 × 5kg columns
 
Yield Combined(Steps 2 & 3)                                65% → 75%
 

Continuous Flow

Process Intensification Examples

Example 1: Carbon Footprint                                   20% reduction
 
Example 1: Process Time                                          250h → 110h
 
Example 2: Carbon Footprint                                  85% reduction
 
Example 2: Process Time                                         400h → 250h
 

Tools Driving Sustainable Process Innovation

  • GreenSpeed: Real-time PMI, water, solvent, and CO₂ analysis linked to electronic lab notebooks.
  • DOZN™: Quantitative green chemistry tool measuring alignment with the 12 Principles of Green Chemistry.
  • Synthia™ Retrosynthesis: AI-enabled smart route design supporting greener synthetic pathways.

Get the Full White Paper

Access Merck’s real-world sustainability improvements, quantitative case studies, PMI analysis, and continuous-flow redesign insights — all backed by rigorous experimental data.

The life science business of Merck KGaA, Darmstadt, Germany, operates as MilliporeSigma in the US and Canada.