The pharmaceutical manufacturing sector continues to expand at a steady pace, but regulatory complexity, operational constraints and sustainability pressures are reshaping packaging and processing strategies across the industry, according to new research from PMMI, The Association for Packaging and Processing Technologies.
A preview of PMMI’s forthcoming white paper, 2025 Trends and Challenges in Pharmaceutical Manufacturing, has been released in infographic form ahead of the full study’s publication in February 2026. The research indicates that the pharmaceutical industry has experienced mid-single-digit compound annual growth rates for several consecutive years, a trajectory that is expected to continue through 2030.
Despite this sustained growth, manufacturers are facing mounting operational and compliance challenges. According to the 2025 Pharma Packaging & Processing Key Trends & Insights Infographic, the most significant manufacturing and packaging issues include keeping pace with regulatory requirements, expanding automation to reduce manual processes, managing space and footprint constraints, addressing serialization and aggregation demands, strengthening supply chain management, and improving machine monitoring, including remote capabilities.
“Breakthrough new drugs such as specialized oncology treatments as well as new applications for existing drugs — like GLP-1 prescriptions for weight management — are leading the charge on industry growth,” said Jorge Izquierdo, vice president of market development at PMMI.
Sustainability remains a growing priority, though one that is often in tension with regulatory and performance requirements. PMMI’s research shows that 78% of pharmaceutical manufacturers have already incorporated sustainability features into their packaging. Among those pursuing further improvements, future material changes are the most common strategy, with manufacturers focusing on lightweighting, increasing the use of recycled content, and exploring compostable and biodegradable materials.
However, material and barrier performance continues to limit the range of viable options. Pharmaceutical products are frequently sensitive to environmental conditions such as temperature and humidity, meaning any alternative materials must meet stringent barrier requirements before sustainability gains can be considered. This constraint, PMMI notes, complicates efforts to advance packaging sustainability without compromising product integrity or regulatory compliance.
Digitalisation and connectivity are also emerging as defining features of future pharmaceutical packaging. The research points to increased adoption of technologies such as radio frequency identification tags, wireless packaging sensors and augmented reality features designed to enhance consumer interaction and product traceability.
Regulatory reporting and documentation present another significant challenge. Seventy-one percent of respondents identified these requirements as a top concern, prompting manufacturers to expand employee training, invest in new equipment and adopt predictive and preventive maintenance approaches to support compliance.
“OEM services to support regulatory compliance are largely in line with end needs, but OEMs and suppliers should consider offering additional assistance around reporting requirements, such as building out digital infrastructures to digitize the reporting process,” Izquierdo said.
Looking ahead, PMMI’s research indicates that original equipment manufacturers are planning to expand machinery capabilities through artificial intelligence-supported processing, including machine learning, enhanced data-gathering sensors, remote troubleshooting functions and upgrade-ready designs. Suppliers able to offer flexible machine portfolios, advanced automation and digitisation features, and ongoing support through remote monitoring, training and education are expected to be best positioned to meet evolving customer demands.
The findings come as the industry prepares for PACK EXPO East 2026, which will take place from February 17 to 19 at the Pennsylvania Convention Center in Philadelphia. With a high concentration of pharmaceutical manufacturers located in the northeastern and mid-Atlantic United States, the event is positioned as a regional hub for packaging and processing professionals seeking to advance projects and evaluate new technologies closer to home.
PACK EXPO East 2026 will feature 500 exhibitors serving more than 40 vertical markets, including over 100 exhibitors with targeted solutions for the pharmaceutical sector, alongside educational sessions and networking opportunities aimed at supporting manufacturers navigating an increasingly complex operating environment.
