Advancing Low-Carbon Inhaler Technology Through Next-Generation Propellant Innovation

As the chemical and pharmaceutical industries progress toward net zero, Orbia Fluor & Energy Materials is supporting this transition through its low global warming potential propellant, Zephex® 152a. The technology enables continued access to essential inhaled medicines while significantly reducing the environmental footprint of pressurised metered dose inhalers, which remain a cornerstone of respiratory care.

Balancing climate ambition with patient need

Pressurised metered dose inhalers are widely used in the treatment of asthma and chronic obstructive pulmonary disease, particularly for patients unable to use dry powder inhalers. While clinically essential, conventional hydrofluorocarbon propellants carry a high environmental burden, placing the sector under increasing pressure to decarbonise.

Zephex® 152a delivers around a 90% reduction in global warming potential compared with legacy propellants. Crucially, this is achieved within existing device formats, preserving usability, clinical performance and patient familiarity, ensuring emissions reductions without compromising continuity of care.

Supporting system-wide transition

The benefits of Zephex® 152a extend across the healthcare ecosystem. It enables pharmaceutical manufacturers to decarbonise established inhaler portfolios without the need for device redesign or changes to treatment pathways, while ensuring patients continue to receive proven and effective therapies.

For healthcare systems, it provides a practical route to reducing emissions associated with respiratory care, supporting broader net zero objectives without compromising clinical outcomes.

Reducing emissions through manufacturing improvements

Alongside product innovation, Orbia Fluor & Energy Materials has implemented targeted improvements across its manufacturing processes, with a particular focus on reducing emissions associated with quality control sampling.

Historically, fugitive emissions from legacy Zephex® 134a processes were approximately 1,412.8 tonnes CO₂e per year. Through process redesign and the transition to Zephex® 152a, this has been reduced to 135.5 tonnes CO₂e, delivering a reduction of 1,277.3 tonnes CO₂e.

Further optimisation of sampling frequency has contributed an additional 33.8 tonnes CO₂e reduction, reinforcing continued progress in improving operational efficiency and emissions performance.

A step change in environmental performance

These improvements deliver a clear and measurable reduction in environmental impact, including:

• Approximately 90% reduction in product global warming potential
• Significant reduction in fugitive emissions during manufacture
• Lower Scope 1 emissions intensity
• More efficient and tightly controlled production processes

Taken together, they demonstrate how targeted process optimisation, when combined with next-generation chemistry, can deliver meaningful and scalable environmental gains in industrial manufacturing.

Delivering at scale through collaboration and looking ahead

Scaling from pilot to full production required close coordination across engineering, operations, process safety, quality and manufacturing teams. This integrated approach ensured the facility was delivered safely, reliably and in line with regulatory expectations, while embedding sustainability into routine operations from the outset.

Zephex® 152a demonstrates how lower-impact propellant chemistry, combined with continuous manufacturing improvement, can deliver meaningful emissions reductions at scale while maintaining essential clinical outcomes.

To learn more, contact the Orbia Fluor & Energy Materials team via https://www.orbia-fem.com