Watson-Marlow Fluid Technology Group – BioClamp

Innovation of the Year for a product or service

BioClamp® is a plastic union clamp (Tri-Clamp), specifically designed to provide hygienic, non-contaminating joints in busy pharmaceutical and bioprocessing laboratories. The clamp was originally launched in 2011 as an ideal solution for single-use critical fluid transfer lines and provides secure attachment of sanitary fittings for customers across the biopharmaceutical industry.

The challenge
Climate change is a major global challenge that requires international collaboration across industries to combat environmental impact. Much of the life science industry has set net zero targets with 2030 and 2050 as key dates to achieve significant progress. Watson-Marlow has committed to targets approved by the Science Based Targets initiative (SBTi), aiming to reach net-zero for scope 1 and 2 emissions (emissions that are in its direct control) by 2030, and scope 3 emissions (those the company is indirectly responsible for, up and down its value chain), by 2050. 

Single-use technologies are often considered as conflicting with environmental goals, however alongside their sterility and commercial benefits, reduced cleaning, sterilisation and smaller footprint can actually offer sustainability benefits over steel alternatives.

The solution
BioPure, a leading provider of single-use solutions and part of Watson-Marlow Fluid Technology Solutions (WMFTS), has refined the design and manufacturing of its single-use sanitary clamp to produce sustainability benefits for users.

A life cycle assessment (LCA) was applied, in collaboration with the University of Exeter, to ensure the optimisations made would deliver maximum results. The LCA identified that upstream processing of raw material in the supply chain contributed to 51% of the impact for BioClamp as the creation of Nylon has the largest impact on the environment in terms of carbon generation, contributing the most to the overall impact of the product. The LCA also highlighted opportunities to further reduce the carbon footprint associated with on-site manufacture.

Following this assessment process, BioClamp was redesigned with the intention of making the manufacturing operation as efficient as possible. The hinge of the clamp was redesigned to remove the pins and replace with a snap fit feature. This not only removed additional components, but the advanced ergonomic hinge makes BioClamp easier to close and simplifies the assembly process, with quick changeovers to improve user experience and enhance efficiency. The updated design also delivers reduced distortion on polymeric fittings when subjected to heat.

On top of this re-design, there was a significant reduction in the waste produced, through enhanced manufacturing efficiency, improved sorting and recycling processes, and the transition of all manufacturing facilities to a renewable energy supply. 

The results
BioClamp is now designed and manufactured to be 13% lighter than the previous model, using less nylon and reducing fuel used during transportation. A 26% reduction in carbon dioxide emissions across the full lifecycle of the product has been achieved, which demonstrates the potential gains that can be made across the industry if similar approaches are taken. 

Looking to the future
The pharmaceutical industry relies on a complex network of suppliers and this intricate supply chain requires collaboration and engagement at every level to achieve any meaningful advancements in sustainability. 

This project emphasises the significant impact that can be achieved through rethinking manufacturing approaches. If life cycle assessments are applied across the supply chain, the impact could be significant, enabling the delivery of life saving therapies without costing the earth. By reimagining both the design and production methods, the project also demonstrates how sustainability-driven changes can improve the end-user experience.