4P Framework: Planet

Crucell’s introduction of the Flex Factory^® has exciting implications for the planet, as well as for our business of healthcare innovation. In this ‘lean and green’ manufacturing setup, the use of disposable equipment eliminates the need for complicated cleaning and sterilization between production batches. This translates into substantial environmental gains, compared to traditional biopharmaceutical manufacturing in stainless-steel bioreactors. Reductions of 87% in water consumption and 25% in carbon footprint have been calculated.¹

Less dramatic, but very worthwhile, examples of environmentally friendly initiatives are flourishing throughout the company. Local initiatives of interest include the switch to 100% ‘green’ electricity in Leiden and the cold box recycling program in Sweden (see the section on responsible supply chain management). The refurbishment of a redundant manufacturing facility in Switzerland is an example of recycling on a large scale.

In other areas, Crucell is leveraging its global reach to achieve sustainable efficiency gains, with spin-off benefits for the environment. In 2009 we have successfully reduced freight, despite growth in vaccine sales, by bundling deliveries and implementing a minimal order policy. Global policies and tools, such as the new procurement policy, will facilitate the choice for green suppliers and rationalize shipments. Crucell used to have a large base of suppliers for a company of our size, which is environmentally wasteful as well as operationally inefficient. This situation, a legacy of Crucell’s history as three separate organizations, has successfully been addressed.

In 2009 we pursued our development of ‘green’ IT through virtualization and more efficient data storage. Use of WebEx and teleconferences rather than travel was encouraged. Our marketing & sales teams made good use of Brand.net, an online platform, to streamline communications with distributors and suppliers: marketing materials can be picked up from the website instead of being sent by post or courier.

¹

Sinclair A, Leveen L, Monge M et al., The Environmental Impact of Disposable Technologies, Biopharm International, November 2008.

As promised in last year’s CSR chapter, we have explored options for improving packaging and initiated changes where possible. For example, the 10-vaccine box of Epaxal^®, our hepatitis A vaccine, has been reduced substantially in size. This means we can fit more vaccines on a pallet and make better use of cold chain storage, which is always limited. For this reason, minimizing total storage volume is an important criteria when participating in tenders. This example illustrates how the environment, society and Crucell’s business can all benefit from smarter packaging.

Environmental issues were carefully considered when packaging was being changed in accordance with the Crucell global rebranding. This presented our Regulatory Affairs team with a dilemma, because of the stringent regulations governing healthcare products. Team leader Wolfram Schlimme explains: “We considered using recycled paper for the package inserts, but we had to reject this idea on regulatory grounds. The paper has to be very thin to fit in the smallest possible box, but not transparent as it is printed on both sides. Recycled paper is not strong enough to guarantee that it will not tear—which would lead to recall of the product. Using thicker recycled paper would require a bigger box, and therefore larger cold storage and transport facilities, increased costs and greater energy use. Net result: no environmental gain.” This dilemma is a good example of the complexity of factors that must be weighed up in our highly regulated industry. Recycled carton will be used for the new product packaging.

The first graph below shows the total energy consumption in killowatt-hours (kWh) at Crucell facilities involved in product manufacturing and development, which together employ over 90% of our workforce. A 2.52% decrease in energy consumption in 2009 relative to 2008 can be seen.

Energy use includes electricity, natural gas, oil, and other fuels such as gasoline and diesel, all of which are converted to kWh. Electricity (from the grid) is Crucell’s primary source of energy. Crucell’s total energy consumption in 2009 is equivalent to that of approximately 3413 average households (which consume 17,906 kWh). In 2008 Crucell’s total energy consumption was equivalent to 3502 average households.

The second graph shows the total water consumption in cubic meters at Crucell facilities involved in product manufacturing and development, which together represent over 90% of our global workforce. A 4.54% decrease in water use in 2009 compared to 2008 can be seen. Dividing the total water consumption by the number of employees allows comparison of annual water use per employee: 194 m³ in 2009 compared to 221 m³ in 2008. Crucell’s water is sourced from the grid.