The implementation of Life Cycle Assessment and related methods in green chemical process and synthesis design strongly supports the development of greener concepts on the basis of deep and profound insights into the dependences between the selection of compounds and process parameters and the resulting environmental impacts. This review article provides an overview on things to know about LCA in general, specifics to be considered during its application in the field of chemical (re-)designs and current application examples from emerging research areas such as active pharmaceutical ingredient manufacturing, nanotechnology, flow chemistry, process intensification under harsh synthesis conditions, process integration, waste treatment, the use of alternative energy sources or solvents as well as chemistry based on renewable resources.

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As the demand for new drugs is rising, the pharmaceutical industry faces the quest of shortening development time, and thus, reducing the time to market. Environmental aspects typically still play a minor role within the early phase of process development. Nevertheless, it is highly promising to rethink, redesign, and optimize process strategies as early as possible in active pharmaceutical ingredient (API) process development, rather than later at the stage of already established processes. The study presented herein deals with a holistic life-cycle-based process optimization and intensification of a pharmaceutical production process targeting a low-volume, high-value API. Striving for process intensification by transfer from batch to continuous processing, as well as an alternative catalytic system, different process options are evaluated with regard to their environmental impact to identify bottlenecks and improvement potentials for further process development activities.

Rufinamide is an antiepileptic drug to treat Lennox–Gastaut syndrome, in combination with other medications. Herein, several batch and continuous process routes to rufinamide are analysed and optimised regarding their environmental impact, to finally predict a fully continuous, telescoped process route.