Green Chemistry: The Hidden Profit Center in Modern Manufacturing

In a recent discussion with Dr. John Warner, we looked at how green chemistry is helping the pharmaceutical industry develop more sustainable materials and processes. 

While more and more companies are adopting these principles, it isn’t solely a compliance issue. Forward-thinking companies are embracing green chemistry for a much simpler reason: it can significantly impact their bottom line. 

Dr. Robert Fleming, co-founder and CTO of Artefact—a pioneer in sustainable composites and biomaterials—has witnessed firsthand how implementing green chemistry can create substantial financial benefits. We spoke with Dr. Fleming to learn more about how manufacturers can leverage green chemistry to drive profitability.

The Evolution of Green Chemistry in Manufacturing

Approaches to environmental considerations—or anything resembling green chemistry—have transformed dramatically over the years. 

"In my early career, the environmental, health, and safety (EH&S) mindset was primitive; it was only about following regulations—I've seen my share of explosions and fires,” Dr. Fleming said, adding that he started noticing a shift in the mid-1990s.

"When I worked at 3M, we began thinking about the full product lifecycle and were challenged to consider safety, efficiency, and waste during manufacturing,” Dr. Fleming said, explaining that  this approach led to significant financial benefits. 

“We developed water-based and solvent-free chemistries that allowed us to save many millions of dollars in a new roll-to-roll manufacturing line.” 

Visit Artefact's website to learn more about their biomaterial products. 

Dr. Fleming sees a similar shift happening with manufacturers today.

"I believe we're approaching that inflection point, where consumers are more educated about the hazards of microplastics and BPA and are fed up with the status quo," he observed. “I see change coming." 

Direct Profit Opportunities from Green Chemistry

By implementing green chemistry principles, manufacturers can realize significant financial benefits in several key areas: 

• Reduced capital and operating expenses
  Implementing green chemistry principles can significantly reduce both upfront investment and ongoing operational costs. Dr. Fleming's experience at 3M provides a compelling case study:
  
  "My first new product developed at 3M was a solventless, reactive, urethane adhesive-coated roll-to-roll. This led to a $25 million solvent-free production coater we installed in Texas," he said, explaining that solventless production coaters require significantly less capital to install compared to traditional solvent-based systems. By eliminating the need for expensive thermal oxidizers to burn solvent emissions, 3M realized substantial savings. 
  
  "It was a win-win,” Dr. Fleming noted. “It's better for the environment; it's more efficient; and it's less capital.”
  
  Advanced manufacturing technologies, including AI, are further enhancing these opportunities today, enabling companies to optimize processes and identify new efficiencies in sustainable production.
  • Circular materials and resource efficiency
    Green chemistry transforms waste into profit by creating new value streams through material efficiency. 
    
    “There is a real opportunity when it comes to circular materials, meaning taking byproducts from one industry and using them in another,” Dr. Fleming said, explaining that this approach can also create financial benefits across sectors—from agricultural waste becoming industrial raw materials to manufacturing scrap being recaptured and reprocessed. 
    
    “If you have one part of a plant used for food, instead of just throwing the other part away, that can be used for products,” he noted. “There's so much material that can be used efficiently rather than discarded."
    
    Bio-based chemistries represent another promising frontier in this space. “I see big opportunities going forward by implementing bio-based chemistries," Dr. Fleming said, adding that his current venture, Artefact, is putting these principles into practice.
    
    “We're developing high-performance bio-based chemistries and resin formulations, natural composites, and a very efficient, capital-light molding process. Our molded products have a carbon footprint 10 times lower than a comparable product.”

Implementing Green Chemistry: Strategy and Overcoming Challenges

Despite the clear financial benefits, some manufacturers remain hesitant to embrace green chemistry. Dr. Fleming recognizes this reluctance, comparing it to skepticism he encountered with other transformative technologies: “I remember having debates with some of my colleagues about the first electric vehicles, but now they're everywhere. People were also skeptical about solar power in the early days, but now it is ubiquitous.”

For companies looking to maximize profit by implementing green chemistry principles, Dr. Fleming suggests three key ideas: 

• Start with organizational culture
  "It has to be in the DNA of the company,” Dr. Fleming said. "Values, vision, and mission." Creating this foundation requires a commitment from leadership combined with supporting business processes. 
• Focus on new products, not retrofits
  When considering where to apply green chemistry principles for maximum profit, Dr. Fleming has a clear recommendation: 
  
  “I believe the biggest opportunity for green chemistry is in the new product space and disruptive supply chains,” he said, explaining that trying to replace existing products with greener alternatives often faces resistance. 
  
  “In some cases, customers will tolerate inferior performance for a greener option, but this is still rare. We have to produce high-performance products with greener chemistry—the product doesn't have to be 'the same,' but it does need to perform.”
• Partner with green chemistry experts
  For manufacturers without extensive in-house R&D capabilities, strategic partnerships can accelerate the adoption of profitable green chemistry initiatives. “To really benefit, you have to have the right people with the right skills—good people with the training and expertise, as well as the values, who are really excited about sustainable green chemistry.” 
  
  He specifically highlighted GL CHEMTEC's capabilities in this area: “I've worked with GL CHEMTEC for years, and I know their expertise. In my mind, GL CHEMTEC is really at the cutting edge of this whole field."

GLC: Your Trusted Green Chemistry Partner

GL CHEMTEC is passionate about your success and committed to solving your most complex chemistry challenges. We offer fast, flexible, cutting-edge solutions to take your green chemistry initiatives to the next level. Our commitment to a collaborative partnership means we scale and adapt precisely to meet your evolving needs.

GL CHEMTEC provides:

• A unique combination of expertise in small molecules and polymers, tailored to the target.
• Integrated solutions that accelerate early-stage API development and innovative drug delivery solutions, with seamless continuity from R&D to manufacturing.
• Strong organic polymer expertise and advanced materials applied to medical devices, drug delivery, and ophthalmic applications.
• Unmatched expertise in sustainable polymer design and development.
• North American facilities, offering a reliable alternative to overseas supply chains and partners.
• A highly customer-centric culture and a 23-year track record of success.
• ISO 9001:2015 and ISO 13485:2016 certifications.