Global Med Tech company – Wellspect – halves their climate footprint and almost completely eliminates water consumption with their new updated coating process.
Mölndal, 10 November. Global Med Tech company Wellspect, based in Mölndal Sweden, has managed to halve the climate footprint and almost completely eliminate water consumption from its production process used to create the unique LoFric® coating on all the company's catheters. In development for several years at the Mölndal facility, Wellspect has worked in close collaboration with their material and process developers within the Research & Development department and their production engineers. It’s been a challenge, but now the fully automated process is ready to deliver catheters with this new coating to customers around the globe.
We are taking a big step for sustainability with the new process and are extremely proud of what we have achieved here in Mölndal, says Svenn Poulsen, Group Vice President Wellspect.
In 1983, Wellspect launched the world's first intermittent hydrophilic catheter, LoFric. The catheter's surface coating mimics the body’s internal environment, which allows for a smooth insertion and extraction, supporting good bladder health in both the short and long term. All catheters undergo an advanced coating process to obtain this unique surface.
Production of LoFric Catheters
A big leap forward
Aligned with the expanded catheter production and equipment replacement, the company has modernized and streamlined its process technology. This presented an opportunity to take a leap forwards by replacing process chemicals with more environmentally friendly alternatives, in compliance with industry regulatory requirements. But they did not stop there, Wellspect decided to take an even bigger step forward than what was requested, which resulted in the new coating process.
Halving the climate footprint
Wellspect has managed to halve the climate footprint of the coating process through minimal use of environmentally harmful chemicals – the main process chemical is now bio-based, i.e. of renewable origin. In addition, energy consumption has been halved, the factory uses 100% renewable energy, some of which is sourced from self-produced solar power, and water consumption has been reduced by 98%.
Solar panels have been installed at the Wellspect site in Mölndal, Sweden
The most important requirement - maintained quality
Both Wellspect and catheter users want to see catheters that contribute to a reduced climate footprint, but the most important requirement for the new process is that the catheters' unique properties are retained, and that we continue to maintain the same quality and patient safety of our coating properties. The company has verified this according to the industry's extensive and strict regulations.
Open dialogue with local authorities
With the changes to the business, Wellspect has been required to apply for a new environmental permit. As the development of the new process has taken a long time, the company has enacted open dialogue with local environmental authorities to achieve these new standards – both during the development period and the permit process.
It’s not very common for companies to apply for a permit for such a major change in operations, which in this case also means a major step forward with regards to environmental impact. We had good conditions, a good plan and had a positive experience. It feels incredibly good that we have our new permit and that we now can start delivering what we promised, says Maria Berntsson, Manager EHS at Wellspect.
Maria Berntsson, Manager EHS at Wellspect
Close collaboration with operators and maintenance technicians
A cross-functional team has worked on the challenge of scaling up capacity from laboratory scale to industrial scale. The new process is fully automatic, and the project team has included operators and maintenance technicians to ensure a safe and efficient workplace. The process will also be implemented within Wellspect's other manufacturing unit in Kazan, Turkey, and will be the standard for any future production expansion, both in Sweden and abroad.
Increased focus on sustainability
The company's new process uses digital tools to ensure quality and increase production efficiency. This has led to a reduction in waste, which is another key component of Wellspect's sustainability initiatives and contributes to the UN's global goals for 2030 – specifically goals # 9 "Sustainable industry, innovations and infrastructure" and # 12 "Sustainable consumption and production".
This project is a clear example of the challenge of balancing demands for a better environment, better working environment and a better financial outlook while at the same time maintaining the users' positive experience, concludes Svenn Poulsen.