Production

user requirement specification of Equipment

User Requirement Specification is a specific document where end user generally defines needs, target, goal and their expectation for a system, service and product. This is actually blueprint for the development personnel and it help to ensure that the product meet the target for the specific group.

A standard User Requirement Specification includes information about the user group, targeted use of the product, functional requirements, Operational requirements, and performance requirements. It also contains constraints or limitations.

A standard User Requirement establishes a better understanding between the stakeholders regarding a defined outcome; also sets a specific goal for the end-user and helps to save the project, and product delivery time the best thing is its budget-friendly; the user can previously estimate the cost of the specific project.

URS is generally developed by the buyer defining all listed requirements. After the development of a URS, the user sent it to the equipment manufacturer to prepare it as per predefined criteria.

A poorly developed URS is always creating confusion for the manufacturer, you can see the poorly written URS at the manufacturer’s end and If you don’t know how to write URS then you can ask standard URS template from the manufacturer, they are happy to help you. If supplied Template is found near your requirements then you can go with a modified version.

User Requirement Specification when disregarded?

A confusing URS is always disregarded. If the manufacturer can’t read you then the faulty or wrong machine can be developed which can destroy your project and A meaningful and well-written user requirement specification saves time and money; also reduce misunderstanding among the manufacturer.

A series of emails may generate to explain your requirement to the manufacturer which may express your poor level of understanding of the specific requirement also create of the high chance of wrong specification delivery and You have to express the requirement what exactly you are looking for in your User Requirement Specification (URS).

Keep it simple, Specific, and Better user requirement specification creates better outcomes.

Requirements of user and support design, qualification activities, operations, commissioning, and maintenance are mainly present on the URS. It’s good to set your mind at the start of your dream project.

According to Mark R. Smith, MD, Realtech,

“A standard URS shall be clear, jargon-free, easily readable, not hard to understand which helps to software engineer and Designer clearly readable and understandable of the user requirement with minimum cost and maximum output”.

Types of Requirements

There are several types of requirements that are depicted here.
[] Business Requirements
[] Functional Requirements
[] Stakeholder Requirements
[] Non-Functional Requirements
[] Transition Requirements

What thing to consider for user requirement specification (URS)?
Two main things shall be considered during the writing of URS, number one: What shall be included and number two what shall not be included.

What to include:

During the writing of the URS, the actual information shall be included in the URS. More information may require for big projects and less for a small project the basic of all URS shall be specific. Unknowingly including a feature that is not available in the market is the same as knowingly ruining your project.

Knowing then any feature should be included in the URS. The most important thing is to include only those specifications that are necessary. Features that will never be used need not be included but the facility to use updated features can be retained.

What not to include:

Ambiguous words or terms, Features that are not easy to understand, and that no one has yet used, features that are not user-friendly and will never be used, and features that are overpriced but less important shall be avoided.

How to proceed with your User Requirement Specification?

Before proceeding with your URS, define the responsibility of the stakeholders in your URS then collect all stakeholders’ signatures with designation and date. An approved URS shall be procced to the manufacturer to avoid any wanted circumstances. To sign a document means that you are responsible for it.

What should be included in the Introduction section?

In this section, you should describe more briefly about yourself and why this URS has been raised. Give a short description of your organization. Like “We are Startech is a startup organization in west Virginia. We want to install a high tech tablet compression machine to produce almost 6000K tablets per hour. This user requirement specification (URS) documents the user requirements for producing tablet dosage forms in a tablet compression machine.

The objective of the User Requirement Specification

They clearly describe the goal of the project so that anyone understands it. A brief overview of the project shall be included. Mention the actual purpose of the URS.

Who will write the User Requirement Specification?

Anyone can write URS, who has a thorough knowledge of the system, service, product, or machine in question. But you don’t let someone write something they don’t know about, for example, production personnel can’t write the URS of quality control equipment and vice versa.

How to document a User Requirement Specification?

The user will prepare the URS and another SEM will check the URS and Engineering personnel and the head of the user department will Review the document, finally Head of Quality will approve the URS. Always documented hierarchy shall be maintained.

To write user requirement specifications for a pharmaceutical company equipment following points should be included

1. Front Page: URS no., Revision no., Addendum no., Using Facility shall be mentioned.
2. List of revisions: Revision number shall be mentioned (if required).
3. List of addendums: Addendum to be mentioned (if required).
4. Table of Contents: Write the list content of the URS.
5. List of abbreviations: All abbreviations shall be mentioned.
6. Signature page: Signatory page contains all signatures including Approval authority.
7. Scope: The scope of the URS is to define the specific Equipment/Instrument.

8.0 Procedural Document Requirements:

This part gives information about the Equipment / Instrument including the Purpose of the Equipment, Specification, Qualification, etc.
8.1 Name of the Equipment: Name of the equipment to be mentioned here, if possible, and Model No. to be defined here.
8.2 Purpose of the Equipment: Purpose of the Equipment shall be clearly defined here.
8.3 Number of Equipment Required: Require quantity of the Equipment/Instrument shall be defined here.
8.4 Qualification: A list of qualification documents shall be mentioned here.
8.5 Specification of Equipment: All major specifications of the Equipment/Instrument shall be mentioned here.

9.0 Operational Requirements:

9.1 Vendor Scope: The Vendors scope shall include the Supply, Installation, and Documentation including calibration certificates, User training, and Details of service/maintenance contracts available.
9.2 Operation: Basic operative characteristics including Data logging (21 CFR part 11), controlling system, capacity, safety, and protection, the capacity of basic function, etc.
9.3 Options and Ancillaries: The vendor should identify, where applicable, their standard equipment that fits this specification. The vendor shall (where possible) also provide costs including, A range of additional maintenance support and services., Any additional accessories to fulfill the requirements indicated in section 9.2.
9.4 Interfaces: A user-friendly control system is required, that can allow system operation with a minimal amount of training.
9.5 Data and Security: If required, data and security articles are to be clearly defined here.
9.6 Environment: Instruments/Equipment’s operating environment should be clearly defined here. The operating area must fit with the specific Instruments/Equipment in such a way that it can be operated without any difficulty.

10.0 Constraints

10.1 Milestones and Timelines: A projected timeline and milestone may be set here.
10.2 Compatibility and Support: The internal components of the system must be compatible with, and resistant to, the materials used during operation. Operating power to be mentioned here.
10.3 Maintenance Requirements: The manufacturer should supply details of any maintenance/breakdown packages available.
10.4 Procedural Constraints

11.0 Life Cycle

11.1 Development Procedures: Future development procedures are to be mentioned here.
11.2 Testing Requirements: See Section 11 for a detailed matrix of the validation testing requirements.
11.3 Delivery Requirements: On supply, the following documentation should be supplied: Operation and maintenance manual (including manufacturer’s recommendations for maintenance schedules). Calibration certificates. Parts list and spare requirements. System specifications.
11.4 Support: The vendor must supply details of all service and maintenance requirements of the equipment. The vendor must also supply details of any service and maintenance support that they can supply.

12.0 GMP Requirement: A list of cGMP requirements shall be mentioned here.
13.0 Utilities Available at The Site of Installation: Utilities shall be described here including the power supply for the machine/equipment.
14.0 Documentation Requirement: A list of documents shall be described here such as Operation, cleaning, and maintenance manuals for equipment as well as the operation, Installation instructions/ guideline, other drawings (such as Mechanical, electrical, instrumentation, etc.), IQ/OQ documents & operating manual., Instrument calibration / Qualification certificates traceable to the national reference standards, Guaranty/ warranty certificates for the equipment, Shipping checklist, and Hardware design specification.
15.0 Terms and Conditions to Be Included in The Quotation: All the terms and conditions shall be described here.
16.0 All the discussion shall be noted here and contact personnel details shall be mentioned at the end of the discussion details.
17.0 Annexures: Mention annexures if there are any.
18.0 Validation Requirements:
The following details the test requirements for documentation, testing, and the stage of the project at which they must be provided/performed. These requirements are a minimum tariff, and the vendor is required to include any documentation, not already requested here, which is considered necessary to support the successful validation of the system.

Which things to follow to write a Modern User Requirement Specification?

From the discussion till now we know what to add to our URS and what not to add. Ambiguity to be avoided as much as possible should be written clearly so that anyone who reads it can understand it. Ambiguity is the enemy of any project’s success and expressing yourself as accurately as possible is possible. Communication must be done in an unambiguous manner to achieve good results; Your project will be successful when you are able to convey your message to others.

To write a best User Requirement Specification you need to keep the following points in mind:

user requirement specification
user requirement specification

1. Focus on Single Requirement:

Check each requirement to be developed and how it is tested. Project success depends on each effective requirement which is really a demand to the project. Avoid unnecessary requirements which really not essential to the project.

2. Avoid Haziness

Your URS must be clearly written. Use a Simple Sentence. No confusing word. Just say what you want and what not.

A user requirement specification should be clearly written, using simple sentences, and without ambiguity. Examples of ambiguous words are:

[] Easy
[] Strong
[] Improve
[] Fast
[] Slow
[] Enough
[] User friendly

What exactly are you meaning “Fast”? this term is theoretical; you can’t actually express your requirement using the word “Fast”. It is hard to measure. Avoid any abbreviations, acronyms, and jargon words (words and phrases, that are not generally understood).

3. Go with the SMART Approach

[] S for Specific
[] M for Measurable
[] A for Achievable
[] R for Realistic
[] T for Time-bound

SMART [Specific, Measurable, Achievable, Realistic, Time-bound) targets offer a decent way to confirm your URS is well-defined and supportable.
Specific: All requirements mentioned in the URS must be specific, clear, and jargon-word-free. Don’t add any unnecessary requirements like easy and fast. Mention the actual specification.

Measurable: Reequipment must be measurable, don’t state anything which can’t confirm by testing or examination. Always avoid theoretical statements like rapid and swift. It can’t measure, you can’t prove that your requirements just met the specification until it is measurable.

Achievable: Never set a requirement which is can’t achieve with help of current technology. A feasibility study shall be done before setting any requirements. You can’t set any requirement which is technically impossible to achieve. It is wise to study well before adding features that you have no idea about. If even then you cannot be confirmed, then seek an expert for help. It is not right to add any feature without knowing it.

Realistic: It’s important to be realistic when determining the list of requirements. Sometimes technically achievable requirements may not be realistic due to regulatory requirements, time restrictions, Budget constraints, or other limitations.

Time-bound: A specific time frame shall be fixed to obtain your project. Even after finishing everything and if the specified time is not fixed, then any project may fail.

4. Organize

Organize your word choice and think carefully about it. Generally, the word “Shall” and “will” define the actual requirement which must be met. Word like “May” and “Could” use to define goals than are expected but not necessarily requirements. So, when you want the requirement must be met then use shall/will and use may/could for not mandatory cases.

5. Control Changes to the Requirements

Any type of changes may require during creating your list of requirements. Changes to the specification of the specific requirement shall be controlled. If any type of change directly affects the requirement, then the requirement shall be updated and a new version shall be created.

6. Requirements Must be Testable

Requirements shall be written in a such way that they can be tested and Specific requirements shall be traceable through the life cycle of the system/service/equipment/instruments.

7. Structural Products

Two types of products may be used as structural products & custom applications; for custom applications, the manufacturer must describe every process step to the user. For structural products, the process steps must be aligned with their predefined specification.

8. Vendor Audit

Most of the cases Regulated companies are most aware of their vendor for periodic assessment. All types of assessment/re-assessment perform in accordance with the Quality Management System (QMS).

9. Specifications

It is essential for the supplier to thoroughly document both the functionality and design of the system which is a prerequisite to ensure successful product development. Documentation must cover all aspects of the system, including software, hardware, and configuration, to meet all requirements to be established.

10. Training & Documentation

The supplier must agree to provide comprehensive system management documentation and provide instructions for both maintenance and use by the supplier and related issues must be agreed upon prior to system purchase.

11. Eliminate Requirement Redundancy

Avoid overcomplicating the system requirements and there is no need to bulk it up by duplicating it. Avoid duplication. Duplicating your documents may require more testing, documentation, and review time, making the project and time progressively longer Don’t include anything which is related to money or finance.

What is the difference between data and information

12. Embrace the Opportunity to Evaluate Vendors

Conducting audits on suppliers may include asking the following questions:
[] Security
[] Product support
[] End User training
[] Company Overview
[] Use of sub-contractors
[] Service delivery process
[] QMS application at the company
[] Development product life cycle
[] Key products development plans
[] Organization, roles, responsibilities, & training

13. Don’t be intimidated by your vendor comparisons

Utilize your URS to evaluate different vendors & note their advantages and disadvantages. If new information is found during the initial stage, feel free to revise your approved URS accordingly through the change control process. It is acceptable to make modifications or adjustments to the requirements to fit your needs until the final approval of the URS and it shall be revised the approved User Requirement Specification accordingly maintaining proper documentation.

14. What ought to be included in the URS?

The contents of a URS naturally include the following (but are not limited):
[] Functional requirements
[] Operational requirements
[] Technical requirements
[] Interface requirements
[] Data requirements
[] Security requirements
[] Regulatory requirements
[] Maintenance requirements
[] Availability requirements
[] Migration of any electronic data
[] Environmental requirements
[] Constraints to be observed
[] Life cycle requirements

15. Categorize Your Requirements

Categorize Your Requirements as-
[] Mandatory (High)
[] Beneficial (Medium)
[] Good to have it (Low)

16. Subjective Knowledge and Processing Step

To ensure that requirements, your professional knowledge is essential but not mandatory; if require you can seek help from an SME [Subject Matter Expert]. To identify key requirements of the system Process knowledge is required which are related to the manufacturing/servicing process. Look for the following key points-
[] Experience
[] Knowledge
[] Documentation

17. The requirements may be incomplete or not fully specified

Sometimes the requirements are not fully understood at the beginning of the project; Requirements evolve over time. URS shall be developed as per requirements when information is available. Don’t share incomplete User Requirement Specifications to the manufacturer to avoid any unwanted requirements.

Frequently Asked Questions

Are URS always required for validation?

At the initial stage of system/service/equipment/instruments, then URS is a valuable tool for ensuring the asking requirements. When an existing system is being validated then URS consider as a functional requirement. These two documents can’t be considered as single documents.

What is the benefit of good User Requirement Specification?

Requirements gathering is an important part of a good software/hardware/service/product development project. Good estimation, improved customer satisfaction, reduced cost, and project duration can all fail if good requirements are not selected and sufficient knowledge is not introduced in the selection If you are unclear about what you are delivering, no one can expect anything better from you.

There are Five main questions that shall be asked to develop any project:
[] Why we are doing it?
[] What do we need to do it?
[] What is the benefit?
[] How do we do it?
[] What is the timeframe?

If we fail to estimate project requirements or are unable to assume what is the requirement, can lead to a poor outcome of the project, and also lead to extra manpower, longer duration, and project costing.

Download Your

User Requirement Specification (URS) Template

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Trimming Machine Operation & Cleaning Procedure

Trimming Machine, Purpose :

Trimming Machine, The purpose of this SOP is to describe the operation procedure of Trimming Machine in order to comply with cGMP standard.

Trimming Machine, Scope :

The scope of the procedure is applicable to the Trimming machine at the Dialysis Fluid Production area of XX Pharmaceuticals Limited.

Definitions / Abbreviation:

[][]Trimming machine is a precision machine. It is covered by metal body. This machine consisting of a lever-operated knife and adjustable guides for container surfaces true to required angle.

Operator/Supervisor

[][]Operation and cleaning of the Trimming machine

Executive/ Sr. Executive

[][]Checking and ensuring that the operation and cleaning is performed according to the SOP.
[][]Preparation and timely review of the SOP.

Manager Engineering

[][]Preparation of maintenance schedule and maintenance of the machine.

Manager, Quality Assurance

[][]Ensure that the SOP reflects actual operation, cleaning and maintenance procedure.
[][]Approve the SOP against XX Pharmaceuticals Ltd. Master documents and current regulatory requirements.
[][]Implementation of the SOP.

Procedure :

Precaution(s) :

[][]Ensure that no unauthorized person gains operational access to the machine.
[][]Care must be taken to ensure that the drive units and accessory parts cannot be switched on inadvertently after servicing or maintenance work.

Instruction :

[][]Use Air (1 to 1.5 bar) during operation of Trimming machine.
[][]Keep the machine dry and cool environment.
[][]Keep the air pipe free from any other instrument, naught and coiling during operation and after completion of job.

Machine Assembling :

[][]Setting of in air pipe line of the machine.
[][]Ensure that the air pipe locks are tightly locked and cleaned.

Machine Operation :

[][]Check the machine that there is no abnormal setting of pipe in the machine.
[][]Connect the main electric supply with the socket.
[][]“On” the electric power.
[][]Then “On” the machine control power.
[][]After completion of assembling
[][]Placed the well required position of HPDE Container.
[][]Machine lever-operate HPDE container up the adjustable knife.
[][]Then Knife cutting the container mouth surfaces true to required.

Machine Dismantling :

[][]First “OFF” the air line valve and then remove the pipe from the source and the machine.
[][]“OFF” the machine control power.
[][]Then “OFF” the electric power.
[][]Remove the main power supply form the socket.

Machine cleaning :

Remove dusts from the machine with a dry lint free cloth.
Clean all the machine parts (air pipe and metal parts) with dry lint free cloth.

Annexure:

Annexure I Equipment Use Log Book

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Filter Integrity Test Machine Operation & Cleaning Procedure

Filter Integrity Test Machine, Purpose :

Filter Integrity Test Machine, The purpose of this SOP is to describe the operation and sanitization procedure of filter integrity test Machine in order to comply with cGMP standard.

Filter Integrity Test Machine, Scope :

The scope of the procedure is applicable to the filter integrity test machine at the DFU Production area of XX Pharmaceuticals Limited.

Definitions / Abbreviation:

[][]Filter integrity test machine is a high precision machine. It is covered by special sealing profile with metal body, large size (10 inch) of touch PLC windows. This machine is associated with data control unit with networking system. BPT/ DFT/BDT are loaded into the machine by Supplier.

Responsibilities:

[][]The roles and responsibilities are as follows:

Operator/Supervisor

[][]Operation and cleaning of the filter integrity test machine
[][]Maintaining operation and cleaning log book.

Executive, Production

[][]Checking and ensuring that the operation and cleaning is performed according to the SOP.
[][]Checking the log book.
[][]Preparation and timely review of the SOP.

Manager Engineering

[][]Preparation of maintenance schedule and maintenance of the machine.

Head of Quality Assurance

[][]Ensure that the SOP reflects actual operation, cleaning and maintenance procedure.
[][]Approve the SOP against XX Pharmaceuticals Ltd. Master documents and current regulatory requirements.
[][]Implementation of the SOP.

Procedure:

Precaution(s):

[][]Ensure that no unauthorized person gains operational access to the machine.
[][]Care must be taken to ensure that the drive units and accessory parts cannot be switched on inadvertently after servicing or maintenance work.
[][]The cover must be kept in close position during operation.

Instructions:

[][]Use Nitrogen (7 to 8 bar) during operation of filter integrity testing.
[][]Keep the machine dry and cool environment.
[][]Keep the nitrogen and other silicon pipe free from any other instrument, naught and coiling during operation and after completion of job.

Machine Assembling :

[][]Remove the SS cover of the Upper side of the machine.
[][]Setting of in and out pipe line of the machine.
[][]Ensure that the pipe locks are tightly locked and cleaned.

Machine Operation :

[][]Check the machine that there is no abnormal setting of pipe in the machine.
[][]Connect the main electric supply with the socket.
[][]Open the flap of automatic data controller (which is situated on the Upper side of the machine) & on the UPS switch.
[][]On the control power of automatic data controller.
[][]Login the password.
[][]After completion of assembling,
[][]Fix the recommended test method setting.
[][]Fix the pre-pressure on the nitrogen pressure gauge setting.
[][]Fix the main-nitrogen pressure setting.
[][]Log in by the main user.
[][]Select the “Program Test” on PLC.
[][]Press the “Page Down” on the PLC of machine.
[][]Select the “Test Technique” (Like: BPT, DFT, BDT).
[][]Press the “Page Down” On PLC of machine.
[][]Set the minimum and maximum range of nitrogen pressure (3000mbar to 4000mbar) as per recommendation of filter certificate.
[][]Press the “Page Down” on PLC machine.
[][]Then set the Product Name, Batch No., and Filter Identity No. on the PLC of machine.
[][]Press “Page Down” and press “Save” button.
[][]Then check all the pipe line again and plug on the nitrogen out line to the filter housing.
[][]Placed the well wetted (soaked by purified water) filter (02 micron) at “O” ring of the filter housing.
[][]Cover the filter housing and tightly locked with TC clam.
[][]After obtaining required steps lock the solution “In” line “OFF” with dead valve and TC clam tightly.
[][]Then press the “Start” button to start the filter integrity testing.
[][]During operation if we want to change (increase/decrease) any parameter or batch no. we have to Press “Stop” button and then put the data again.

Machine Dismantling :

[][]First “OFF” the nitrogen line valve and then remove the pipe from the source and the machine.
[][]Remove the nitrogen line from the filter housing.
[][]Press the “Main Menu” on the PLC of the machine.
[][]Remove the main power supply form the socket.

Machine cleaning :

[][]Remove dusts from the PLC of the machine with a dry lint free cloth.
[][]Clean all the machine parts (silicon pipe and metal parts) with dry lint free cloth.

Annexure:

Annexure I Equipment Use Log Book

Filter Integrity Test Machine Operation & Cleaning Procedure Read More »

Laminar Air Flow Machine Operation, Cleaning & Maintenance

Laminar Air Flow Machine, Purpose :

Laminar Air Flow Machine, The purpose of this SOP is to describe the operation, calibration and cleaning of Laminar Air Flow used for the Filling Area in the Dialysis Fluid unit (DFU) at XX Pharmaceuticals Ltd.

Laminar Air Flow Machine, Scope :

This procedure describes the application of Laminar Air Flow, for the Filling Area of formulated drug product at the XX Pharmaceuticals Limited.

Definitions / Abbreviation:

[][]SOP: Standard Operating Procedure.
[][]LAF: Laminar Air Flow

Responsibilities:

[][]The roles and responsibility is as follows:

Executive, Production

[][]To ensure that this procedure is followed.
[][]To maintain the records properly as per SOP.

Manager, Production

[][]To ensure that this procedure is kept up to date.
[][]To confirm that the SOP is technically sound and reflects the required working practices.
[][]To arrange training on the SOP to all concerned personnel and to ensure implementation of the SOP after training.
[][]Schedule calibration of the instrument at the defined intervals.

Head of Quality Assurance

[][]Approval of the SOP.

Procedure:

Precaution(s):

[][]Ensure the Safety Precaution.
[][]No Water Contact on the switch Board.

Operation

[][]Ensure that all surface area is clean with PVC curtain.
[][]Check the Electric line ON
[][]Ensure that the Laminar Air Flow is cleaned on the day use.
[][]Plug on the electric line. .
[][]Switch on the power its main.
[][]Power on the Laminar Air Flow Light
[][]Switch ON the LAF operation.
[][]Check Pressure Gauge Meter.
[][]Ensure the Reading of air Differential Pressure 150pa-200pa.
[][]Record the Operational data in the Operation Logbook of Laminar Air Flow as per Annexure – II.
[][]Power off the Laminar Air Flow.
[][]Switch off the power from its main.

Cleaning and maintenance:

[][]Clean the outside case of the Laminar Air Flow using a mild detergent or disinfectant (e.g.75% IPA) if required.
[][]Clean the area around the Laminar Air Flow and wipe immediately. Special care should be exercised when cleaning up IPA 75% (usually).
[][]When required, clean all wires and contacts to avoid corrosion.
[][]Inspect the cables of the LAF for any signs of broken insulation.
[][]Inspect the Light Shade Dry Cleaned Cloth.
[][]Rinse through with Purified Water of PVC Curtain.
[][]Make sure that no water Flow to the HEPA Filter, Light Shade.

Annexure:

Annexure I Equipment Use Log Book
Annexure-II: Logbook for daily Operation of Laminar Air Flow.

Laminar Air Flow Machine Operation, Cleaning & Maintenance Read More »

SUPAC Guideline, Scale Up and Post Approval Changes

SUPAC Guideline Purpose

SUPAC Guideline, This guideline provide recommendation mainly to those sponsors of 1.0 New Drug Applications (NDA’s), 2.0 Abbreviated New Drug Applications (ANDA’S), And 3.0 Abbreviated Antibiotic Applications (AADA’s) who want to change during the post approval period

1.0 The components or composition;
2.0 The site of manufacture of an immediate release oral formulation.
3.0 Scale-up/scale-down of manufacture; and/or(Batch Size Change)
4.0 Manufacturing (Process and Equipment)

This guidance (SUPAC Guideline) has been deprived or resulted from the workshop on scale-up of immediate  release drug products directed by AAPS(American Association of Pharmaceutical Scientists) in conjunction with the USPC (United States Pharmacopoeial Convention) and FDA (Drug Administration).

SUPAC Guideline mainly focused on

[][]Levels of change,
[][]Each level of change for recommended chemistry, manufacturing, and controls tests
[][]In vivo bioequivalence tests/or in vitro dissolution tests,
[][]Documentation that should support the changes.

SUPAC Guideline doesn’t comment if compliance/inspection documentation doesn’t affected. Except as specified in this guideline, no post approval changes are affected. These guidelines do not comment on or affect compliance/verification documents issued by the CDER Compliance Office or the FDA Regulatory Authority.

Some useful definitions for SUPAC Guideline

Batch

A certain amount of drug or other ingredient is produced according to a of production order and during the same production cycle, it is intended to maintain consistent character & quality within certain limits.

Dissolution Testing

[][]Case A:
Dissolve Q = 85% in 900 mL (mL) for 15 minutes use of 0.1N Hydrochloride (HCl), USA Pharmacopoeia (USP) <711> Apparatus 1 at 100 rpm or Apparatus 2 at 50 rpm.

[][]Case B:
The multipoint dissolution profile in the application/summary interval is 15, 30, 45, 60, 120 minutes or until the asymptote is reached for the proposed and now accepted formula.

[][]Case C:
Water, 0.1N HCl, And pH 4.5, 6.5 and 7.5 USP buffers (5 separate Profile) Proposed and currently accepted pharmaceutical formulation where Multi-point dissolution profiles performed. Proper sampling should be done in the following locations: Up to 90% of the drug 15, 30, 45, 60 and 120 minutes Resolved from medicines or asymptote Reached. Surfactants can be used with suitable agents Justification.

Validation

Establishing a high level of security with documented evidence Producing a product that consistently meets that requirement for a particular process Given specifications and quality features. Verified the manufacturing process is a process that has been proven to carry out what it claims to be or is represented as. Proof of verification is obtained by If possible, process-based data collection and evaluation from the development phase to the production phase. Verification inevitably involves process certification ( Not only materials, equipment, systems, buildings, personnel) Includes control over the entire process of repeated batches or executions.

1.0 Components and Composition

This section of the guidance focuses on changing pharmaceutical additives. Changes in the amount of active substance are not covered in this guideline. Ingredients or compositional changes that cause the addition of new additives or the removal of additives are defined at Level 3 (defined below), except as described below.

SUPAC Guideline: Levels of change

Level 1 Change

Level 1 changes are unlikely to have detectable impact on product quality and performance.

Level 1 Change, Example

[][]Example 1

Removal or partial removal of an element intended to affect the color or odor of the drug product, Or change printing ink material on another approved material.

Example 2

[][]Changes in excipients, expressed as a percentage of (w/w) Total composition below the next percentage area:
[][]The above mentioned percentage has been demonstrated that the drug substance has been formulated to 100% of label/potency.
[][]Total additive shall not be more than 5%( If a product formulated with Active Ingredient I, Microcrystalline cellulose, lactose, magnesium stearate. Then Microcrystalline cellulose, lactose total quantity shall not be more than 5%.
[][]If any component increases 2.5%, other component shall be decrease at 2.5%; if we increase microcrystalline cellulose 2.5% then Lactose shall be decrease to 2.5% & this is vice versa which is relating to target dosage weight.
[][]Mentioned active and excipients in the formulation shall be multiple targets as it represents the nominal composition for the drug product where any future changes shall be in the dug product based. Based on approved composition allowable changes shall be made.

List of documents required to implement the Level 1 change

Chemistry Documentation
[][]Application / official release requirements and Stability Testing Report.
-Stability test: batch containing long-term stability data Reported in the annual report for one batch

[][]Dissolution Documentation
-Nothing goes beyond the application/official requirements.

[][]n Vivo Bioequivalence Documentation
-None/Nothing else.

[][]Filing Documentation
-Annual report (all information including data on long-term stability).

Level 2 Change

[][]Level 2 changes are changes that can have a significant impact on the quality and performance of the formulation. List of documentation depends on three factors for level 2 documentation. Therapeutic range, solubility and permeability. The range of treatment is defined as narrow or not narrow.

[][]Change in the excipient technical grade (i. e. Avicel PH102 vs. Avicel PH200.)
[][]Excipients changes has been demonstrated as w/w for the respective formulation which is greater than the Level I changes but it shall be equal to or less than the mentioned range demonstrated below.

Table 2: Level 2 Change

[][]The above mentioned percentage has been demonstrated that the drug substance has been formulated to 100% of label/potency.

[][]Total additive shall not be more than 10%( If a product formulated with Active Ingredient I, Microcrystalline cellulose, lactose, magnesium stearate. Then Microcrystalline cellulose, lactose total quantity shall not be more than 10%.

[][]If any component increases 5%, other component shall be decrease at 5%; if we increase microcrystalline cellulose 5% then Lactose shall be decrease to 5% & this is vice versa which is relating to target dosage weight.

List of documents required to implement the Level 2 change

Chemistry Documentation
[][]Application/ official release requirements and batch records.
[][]Stability testing: 1 lot with 3 months accelerated stability data and 1 lot for long-term stability data
[][]Dissolution Documentation
Case A, Case B & Case C required for 1.0 High Permeability, High Solubility Drugs, 2.0 Low Permeability, High Solubility Drugs, 3.0 High Permeability, Low Solubility Drugs.

[][]In Vivo Bioequivalence Documentation
-If the situation is not as described See Case A, Case B, or Case C, the refer to Level 3 Changes.

[][]Filing Documentation
Pre-approval supplement (accelerated stability data with all information) Annual report (long term stability data)

Level 3 Changes

Level 3 changes are those that are likely to have a significant impact on formulation quality and performance. Tests and filing documentation vary depending on the following three factors: Solubility, Permeability and therapeutic range.

Examples: Level 3 Changes

[][]Changes of excipient quantity for a narrow therapeutic drug over the above mentioned Table 1.
[][]Changes of excipient quantity of all drugs beyond those listed in Section Table 2.
[][]Changes of excipient quantity for low solubility, low permeability drug over the above mentioned Table 1.

List of documents required to implement the Level change

Chemistry Documentation

[][]Application/ official release requirements and batch records.
>>Stability test: One batch 3 month accelerated stability data & One batch long-term stability data Reported in one year report.
[][]Dissolution Documentation
>>Case B dissolution profile
[][]In Vivo Bioequivalence Documentation
>>Can be waived with the accepted verified in vivo/in vitro study.
[][]Filing Documentation
>>Pre-approval supplement (accelerated stability data with all information) Annual report (Long term stability data).

2.0 Site Changes

Changes in the site which is owned by company or site of contact manufacturing . No scale up batches, changes in component or composition batch shall not be mentioned/ include here. Selected site shall be possessed cGMP.

Level 1 Changes

Definition of Level
This is really a site to site change where actually no basic changes are made only administrative information are changes all of the control parameter like SOP, Environment, Equipment’s, Facility etc. are same and manpower is fully experienced on the new site in a single facility.

Documentation

[][]Chemistry Documentation
>>No special requirements

[][]Dissolution Documentation
>>No special requirements

[][]In Vivo Bioequivalence Documentation
>>None.

[][]Filing Documentation
>>Only Annual report

Level 2 changes

In the adjacent city blocks where the same equipment’s, environment, SOP’s etc. are used & no change are made except administrative information and the location of the site.
[][]Test Documentation
>>Chemistry Documentation
>>New site Location and updated batch records.
>>Batch long-term stability data reported in annual report.
[][]Dissolution Documentation
>>Official Requirements only
[][]In Vivo Bioequivalence Documentation
>>No issue
[][]Filing Documentation
>>Annual report (long-term stability test data), Changes being effected supplement;

Level 3 changes

[][]Level 3 changes comprise of an adjustment of assembling site to an alternate grounds. An alternate grounds is characterized as one that isn’t on similar unique adjoining site or where the offices are not in contiguous city blocks.

[][]To qualify as Level 3 change, similar Equipment Setup, Environment circumstances SOP’s, and controls should be utilized in the assembling system at the new site, and no changes might be made to the Manufacturing batch records with the exception of regulatory data, area and language interpretation, where required.

Test Documentation

>>Chemistry Documentation
>>New site Location of & updated batch record.
>>Application/compendial release requirements.

Stability:

>>Stability test: One batch 3 month accelerated stability data & One batch long-term stability data Reported in one year report.

Dissolution Documentation

>>Case B: Multi-point dissolution profile ought to be achieved within the utility/compendial medium at 15, 30, 45, 60 and a hundred and twenty mins or till an asymptote is reached. The dissolution profile of the drug product on the contemporary and proposed site must be similar.

In Vivo Bioequivalence Documentation

None.

Filing Documentation

Annual report (long-term stability data).

Level 1 Changes

Change in batch size, as much as and which includes a thing of 10 times the scale of the pilot/biobatch, in which: 1) the system used to produce the take a look at batch is of the identical layout and working concepts; 2) the batch is manufactured in complete compliance with CGMP’s; and 3) the equal well known running processes (SOP’s) and controls, in addition to the same components and production tactics, are used on the take a look at batch and on the overall-scale production batch.

Test Documentation

[][]Chemistry Documentation
>>Similar or as of Application/compendial release requirements.
>>Notification for change & submission of updated batch records in annual report.
>>Long term stability reported in annual report (One batch)
[][]Dissolution Documentation
>>Similar as of application/compendial release requirements.
[][]In Vivo Bioequivalence
>>None.
[][]Filing Documentation
>>long-term stability data (Annual report).

3.0 Batch Size change

Level 1 Changes

Changes in batch length past a aspect of ten instances the scale of the pilot/biobatch, wherein: 1) the machine used to supply the take a look at batch is of the identical design and operating principles; 2) the batch is (are) produced in whole compliance with CGMP’S; and 3) the same SOP’s and controls as well as the identical formulation and manufacturing approaches are used at the take a look at batch and on the full-scale manufacturing batch.

Test Documentation
[][]Chemistry Documentation
>>Similar or as of Application/compendial release requirements.
>>Notification for change & submission of updated batch records in annual report.
>>Long term stability reported in annual report (One batch) & three months accelerated stability data for One batch
[][]Dissolution Documentation
>>Case B testing.
[][]In Vivo Bioequivalence
>>None.
[][]Filing Documentation
>>long-term stability data (Annual report).

4.0 Manufacturing

Manufacturing adjustments/Change might also affect each system used in the production process & the technique itself.

A. Equipment

Level 1 Changes

Definition of Change

This class includes: 1) alternate from non-automated or non-mechanical system to automatic or mechanical equipment to transport elements; and a couple of) trade to opportunity device of the identical layout and working ideas of the equal or of a distinct potential.

Test Documentation

[][]Chemistry Documentation
>>Similar or as of Application/compendial release requirements.
>>Notification for change & submission of updated batch records in annual report.
>>Long term stability reported in annual report (One batch)
[][]Dissolution Documentation
>>Similar as of application/compendial release requirements.
[][]In Vivo Bioequivalence Documentation
>>None.
[][]Filing Documentation
>>Long-term stability data (Annual report).

Level 2 Changes

[][]Definition of Level
>>Equipment Change to a different design & different operating principles.

[][]Test Documentation
[][]Chemistry Documentation
>>Similar or as of Application/compendial release requirements.
>>Notification of change and submission of updated batch records.
>>Long term stability reported in annual report (One batch) with 3 month accelerated stability data.
[][]Dissolution Documentation
>>Case C dissolution profile.
[][]In Vivo Bioequivalence Documentation
>>None.
[][]Filing Documentation
>>long-term stability data (annual report); Prior approval supplement with justification for change;

B. Process

Level 1 Changes

This class includes process adjustments along with adjustments consisting of blending instances and operating speeds within application/validation degrees.
Test Documentation
[][]Chemistry Documentation
Similar as of application/compendial release requirements.
[][]Dissolution Documentation
Similar as of application/compendial release requirements.
[][] In Vivo Bioequivalence Documentation
None.
[][]Filing Documentation
Annual report.

Level 2 Changes

Definition of Level
This category includes process changes including changes such as mixing times and operating speeds outside of application/validation ranges.
Test Documentation
[][]Chemistry Documentation
>>Similar as of Application/compendial release requirements.
>>Change notification & updated batch records to be submit.
>>Stability testing: Long-term stability for One batch.
[][]Dissolution Documentation
>>Case B Study: Dissolution profile.
[][]In Vivo Bioequivalence study
>>None.
[][]Filing Documentation
>>Long-term stability (Annual Report); Changes being affected supplement;

Level 3 Changes

Application/compendial release requirements.
Change Notification & updated batch records submission.
[][]Stability testing:
Significant body of data available:
three months accelerated stability data for One batch reported in supplement; long-term stability data reported in annual report for one batch.
[][]Dissolution Documentation
Case B dissolution profile.
[][]In Vivo Bioequivalence Documentation
May be waived if a suitable in vivo/in vitro correlation has been verified/established.
[][]Filing Documentation
Prior approval supplement with justification; long-term stability data (Annual report).

[][]In Vitro Dissolution
As per USP/NF Section<711>, to be conducted for 12 individual dosages.

In Vivo Bioequivalence Studies

In vivo bioequivalence study has been demonstrated as below. The actual design style may vary as it can be treated as an intended design guide for drug and dosage form.

[][]Objective:
The drug product which manufacture has been changed its rate and extent of absorption shall be compare.
[][]Design:
The study layout must be a single dose, two-treatment, two-period crossover with adequate washout period among the 2 phases of the study.
[][]Selection of Subjects:
The range of subjects enrolled inside the bioequivalence observe need to be decided statistically to account for the intrasubject variability and to satisfy the modern bioequivalence interval.

[][]Procedure:
>>Each subject should obtain the subsequent remedies:
Treatment 1: Product produced with the proposed change.
Treatment 2: Product produced prior to the proposed change.
>>Following an overnight speedy of at least 10 hours, subjects must get hold of both Treatments 1 or 2 above with 240 mL water. Food ought to now not be allowed until four hours after dosing. Water can be allowed after the primary hour. Subjects must be served standardized food beginning at 4 hours at some stage in the look at.
[][]Restrictions:
>>Prior to and at some stage in each observe section, water can be allowed ad libitum except for 1 hour before and after drug administration. The issue ought to be served standardized food and drinks at unique instances.

List of Narrow Therapeutic Range Drugs: SUPAC Guideline

[][]Aminophylline Tablets, ER Tablets
[][]Carbamazepine Tablets, Oral Suspension
[][]Clindamycin Hydrochloride Capsules
[][]Clonidine Hydrochloride Tablets
[][]Clonidine Transdermal Patches
[][]Dyphylline Tablets
[][]Disopyramide Phosphate Capsules, ER Capsules
[][]Ethinyl Estradiol/Progestin Oral Contraceptive Tablets
[][]Guanethidine Sulfate Tablets
[][]Isoetharine Mesylate Inhalation Aerosol
[][]Isoproterenol Sulfate Tablets
[][]Lithium Carbonate Capsules, Tablets, ER Tablets
[][]Metaproterenol Sulfate Tablets
[][]Minoxidil Tablets
[][]Oxtriphylline Tablets, DR Tablets, ER Tablets
[][]Phenytoin, Sodium Capsules (Prompt or Extended), Oral Suspension
[][]Prazosin Hydrochloride Capsules
[][]Primidone Tablets, Oral Suspension
[][]Procainamide Hydrochloride, Capsules, Tablets, ER Tablets
[][]Quinidine Sulfate Capsules, Tablets, ER Tablets
[][]Quinidine Gluconate Tablets, ER Tablets
[][]Theophylline Capsules, ER Capsules, Tablets, ER Tablets
[][]Valproic Acid Capsules, Syrup
[][]Divalproex, Sodium DR Capsules, DR Tablets
[][]Warfarin, Sodium Tablets

SUPAC Guideline, here by apply for the above mentioned & SUPAC Guideline shall be followed for the same.

SUPAC Guideline, Scale Up and Post Approval Changes Read More »

Container Washing and Handling System of Dialysis Fluid Unit

Purpose :

The purpose of this SOP is to describe the procedure of container Washing and Handling system of Dialysis Fluid Unit at XX Pharmaceuticals Ltd.

Scope :

This SOP is applicable for the Production and Primary Packaging of Dialysis Fluid Unit at XX Pharmaceuticals Limited.

Definition / Abbreviation :

[][]HDPE: High Density Polyethylene

Responsibilities :

[][]The Roles and Responsibilities are as follows :

Operator

[][]To ensure that this procedure is followed.

Executive, Production

[][]To monitor and check the laid down procedure.

Manager, Production

[][]To implement this correctly.

Head of Quality Assurance

[][]To approve the SOP.

Precautions :

[][]Ensure the Proper Safety Instruction Are Followed.
[][]Ensure that the Supply the Water (Potable, Hot & Purified).

Empty Container Washing Procedure :

[][]Send the ERP Requisition to the ware house, then they Provide QC passed Containers from General Warehouse.
[][]Places the containers (50pcs) at the Plastic Pallet and transfer to the container washing room.
[][]Ensure that all utility lines like compressed air, electric line, potable water (hot & normal) and purified water are in attendance.
[][]Put off the stopper plug.
[][]Placed the container perpendicularly (3Pcs at a time) at the washing machine then flow the potable water for 30 sec (inner & outer elevation).
[][]Supply the hot water (50 to 60o) into the containers for 30 sec (inner & outer elevation).
[][]Concluding Supply of Purified water into the containers for 30 sec (inner & outer elevation).
[][]After that washed container staging at the cage trolley, then transfer to the filling room.
[][]Ensure that area cleaning activity is recorded in Cleaning Log book
[][]Check and ensure that Containers Cleaning activity is recorded in respective ‘Equipment log book’
[][]Ensure that all Containers are labeled as CLEANED.

Annexure

Annexure-I: HDPE Container (10 L) Washing Record.

Container Washing and Handling System of Dialysis Fluid Unit Read More »

Product Changeover of Dialysis Fluid Unit

Product Changeover, Purpose :

Product Changeover, To lay down the Procedure of Product Change Over to the Production and Packaging Area during Product to Product changeover and Batch to Batch Changeover for Dialysis Fluid Unit(DFU)

(DFU).

Product Changeover, Scope :

This SOP is applicable for the Concern Personnel of Production and Packaging of DFU Unit at XX Pharmaceuticals Limited.

Definition / Abbreviation :

N/A

Responsibilities :

[][]The roles and responsibilities are as follows :

Operator

[][]To follow the laid down procedure.

Laundry Man

[][]To provide cleaned garments.

Executive, Production

[][]To monitor and check the laid down procedure.

Manager, Production

[][]To implement this correctly.

Head of Quality Assurance

[][]To approve the SOP.

Precautions :

[][]Ensure the proper safety instructions are followed.
[][]Ensure that no previous product is available in the area.

Product to Product Changeover :

[][]Ensure that, all utility lines like compressed air line, steam line, electrical fixtures, air inlet ducts, return air risers, potable water and purified water lines are cleaned and no visible traces of product are present.
[][]Ensure that Outer surface of machine, table, door, floor, walls and ceiling are cleaned.
[][]Ensure that Pre-mixing, Mixing, Storage, Filling Vessel to be clean with plenty of water (First time Potable Water Finally Purified water).
[][]Ensure that area cleaning activity is recorded in ‘Room Cleaning Log Book’
[][]Ensure that all equipments in the area are cleaned according to their respective SOPs and no traces of previous product are visible within the equipment.
[][]Check and ensure that equipment cleaning activity is recorded in respective ‘Equipment Log Book’
[][]Ensure that Span between equipment usage and cleaning is not more than seventy two hours.
[][]Ensure that Balances in the production area are cleaned and accuracy check is done before use.
[][]Ensure that production utensils like scoops, spatula, sieve stand, punch trolley, pallets, BMR table and tool boxes are cleaned as per procedure.
[][]Ensure that all equipments are labeled as ‘CLEANED’.
[][]Ensure that fresh set of gowns are issued to concerned operators.
[][]Ensure that proper environmental condition is maintained in the area and the records of the same are maintained in the specified formats.
[][]Ensure the correctness of Batch Manufacturing Record / Batch Packaging Record.

Batch to Batch Changeover :

[][]Ensure that previous batch material is removed from the production area.
[][]Ensure that all the equipment and their spares are cleaned according to their respective SOPs.
[][]Ensure that equipment cleaning activity is recorded in respective ‘Equipment Log Book’.

Annexure:

Annexure I Equipment Use Log Book

Product Changeover of Dialysis Fluid Unit Read More »

Material and Man Flow of Dialysis Fluid Production Area

Material and Man Flow, Purpose :

Material and Man Flow, To lay down the procedure of Material and Man Flow to the Production and Packaging Area for Dialysis Fluid .

Material and Man Flow, Scope :

This SOP is applicable for the Concern Personnel of Production and Packaging of Dialysis Fluid Unit(DFU) of the XX  Pharmaceuticals Limited.

Definition / Abbreviation:

[][]BOM = Bill of Material
[][]QAD = Quality Assurance Department
[][]DFU= Dialysis Fluid Unit

Responsibilities:

[][]The roles and responsibilities are as follows:

Operator

[][]To follow the laid down procedure.

Laundry Man

[][]To provide cleaned garments.

Executive, Production

[][]To monitor and check the laid down procedure.

Manager, Production

[][]To implement this correctly.

Head of Quality Assurance

[][]To approve the SOP.

Annexure:

N/A

Precautions :

[][]Do not step on the floor with bare foot.
[][]Rub hands with Disinfectant Solution before entering into the Production Area.
[][]Jewelry, Wrist Watch, Finger Ring & Ear Ring is not allowed to Production Area.
[][]No food is allowed to Production Area.
[][]Shoe>Cover >Cap >Apron >Mask.
[][]After wearing company provided dress, stand in front of the mirror and confirm that, clothing is covering full arms and cap is covering all hairs according to the sample photos displayed.
[][]Proceed towards the DFU Unit.

MAN FLOW ( Starting from D Change ) :

[][]Before entering into the primary change room, Personnel should complete secondary change as per procedure.
[][]Enter into the Primary Change Room.
[][]Rub hands with Disinfectant Solution (70% Iso-Propyl Alcohol).
[][]Open the door of Corridor, turn left side and proceed to the Production as well as Container Washing Area of DFU.

MATERIALS FLOW ( Starting from Ware-House, Solid Block ) :

[][]Collect Materials from Cargo Lobby (less than 25 Kg) for dispensing at the Dispensing Booth (GPR009) of General Block.
[][]Ensure that, around 25 Kgs. in a single Bag / Pack transfers directly to the DF Unit Air-Lock.
[][]Ensure that, all the materials dispensed as per BOM are to be needed to transfer to the Manufacturing Area of the DFU.
[][]Liquid Material (Glacial Acidic Acid) is to be collected from the Flammable Storage Area.
[][]Filled Containers (10L) are to be transferred to the Secondary Packaging Area of General Block by using transfer trolley.
[][]The received Filled Containers (10L) are taken to the Packaging Conveyor for proper Wiping, Labeling and Packaging.
[][]Packed Products as a whole batch are to be taken to the Quarantine Area on Pallets for QA Release.
[][]After getting QA Release Slip, the Finished Goods (as a whole batch) are to be transferred to the Central Ware-House through the Warehouse of Solid Block.

Material and Man Flow of Dialysis Fluid Production Area Read More »

Filter Cleaning, Regeneration & Storage System

Filter Cleaning, Purpose :

Filter Cleaning, The purpose of this SOP is to describe the setting, operation and cleaning procedure of Cartridge filter in order to comply with cGMP standard.

Filter Cleaning, Scope :

The scope of the procedure is applicable to the Cartridge filter of  Dialysis Fluid  of XX Pharmaceuticals Limited.

Definitions / Abbreviation:

[][]CIP : Clean In Place

Responsibilities:

[][]The Roles and Responsibilities are as follows:

Operator

[][]Operation and cleaning of the cartridge filter.
[][]Maintaining Equipment Log Book.

Executive, Production

[][]To monitor and check the laid down procedure.

Manager, Production

[][]To implement this correctly.

Head of Quality Assurance

[][]To approve the SOP.

Annexure:

N/A

Precautions :

[][]Hot purified water should be not more than 60oc.
[][]The wash-down valves are in closed position.
[][]Check for any leakage from discharge valve.

Filter Cleaning:

[][]Remove the Filter housing from the Vessel.
[][]Cleaning of filter Cartridge (1.2, 0.45 & 0.2 micron or 1.0, 0.6 & 0.2 micron).
[][]Clean the Cartridge filter (1.2, 0.45 & 0.2 micron or 1.0, 0.6 & 0.2 micron) with potable water.
[][]Soak the Cartridge filter in hot purified water and retain for 30 minutes.
[][]Wash the Cartridge filter 3 times with purified water.
[][]Allow the Cartridge filter to dry in wash bay.
[][]After drying take the Cartridge filter in a Clean poly bag and Stored in Closed ss Cabinet.
[][]After final cleaning affix the ‘CLEANED’ label.

Filter Cleaning, Regeneration & Storage System Read More »

Dialysis Fluid Filling Machine set up, operation and cleaning

Dialysis Fluid Filling Machine, Purpose :

Dialysis Fluid Filling Machine, The purpose of this SOP is to describe the setting, operation and cleaning procedure of filling machine in order to comply with cGMP standard.

Dialysis Fluid Filling Machine, Scope :

The scope of the procedure is applicable to the filling machine at the production area of dialysis Fluid unit of XX Pharmaceuticals Limited.

Definitions / Abbreviation:

[][]LAF = Laminar Air Flow.
[][]PVC = Polyvinyl Chloride.

Responsibilities :

[][]The roles and responsibilities are as follows:

Operator

[][]Operation and cleaning of the filling machine.
[][]Maintaining equipment log book.

Executive, Production

[][]To monitor and check the laid down procedure.

Manager, Production

[][]To implement this correctly.

Head of Plant Operation

[][]To agree the laid down procedure.

Head of Quality Assurance

[][]To approve the SOP

Procedure :

Precautions :

[][]Use face mask, rubber gloves and protective clothing during filling operation.
[][]Turn ON LAF before filling operation.
[][]Connect electric line properly.
[][]Filling vessel valves are in open position.
[][]Check any leakage from discharge valve, silicon pipe and filling piston.

Machine Assembling :

[][]Clean the machine well with lint free cloth.
[][]Assemble the machine change parts and all the connections that are necessary for certain types of Operation.
[][]Attach tightly the silicon pipe (2’’) to the storage vessel (2000L).
[][]Attach tightly the solution transfer pipe (1½’’) to the dosing unit.
[][]Covert the filling machine by the PVC curtain.

Machine Operation:

[][]Lock the chamber lid cover of 200L vessel properly.
[][]Turn the transfer pump ON/OFF key to ON.
[][]Transfer 2000 L solution from storage vessel (2000 L) by opening the gate valve of storage vessel.
[][]This system is done by product filling end times.
[][]Turn the filling machine ON/OFF key to ON.
[][]Placed two containers under the dosing nozzle pipe
[][]Wait for two dosing rotation per container (5Liters/Stroke) then push OFF button.
[][]Look the actual filling volume of the containers.
[][]Push the OFF button of filling machine if container supplies insufficient or any other problems.
[][]Check the solution during filling by looking at the vision area of lid cover.
[][]Transfer or sample the solutions by opening the sampling port valve manually.
[][]Push the OFF button to stop the machine and plug out the main electric line to its main.
[][]Record the machine start time, end time and other parameters in the ‘Equipment Log Book’

Machine Dismantling :

[][]Turn the machine ON/ OFF key to OFF the machine.
[][]Remove the solution transfer pipe and filling pipe manually.
[][]Remove the lid cover and turn OFF the stirring.
[][]Remove the electric industrial plug.

Machine Cleaning :

[][]Clean the machine with lint free cloth to remove dust.
[][]Clean the inner elevation of the filling machine by using potable water.
[][]Clean the inner elevation of the filling machine by using hot water.
[][]Clean the inner elevation of the filling machine by using purified water through pipe.
[][]Clean the outer elevation of the filling machine with potable water by rubbing with a lint free cloth.
[][]Soak with a clean dried lint free cloth to remove the water from the filling machine.
[][]Clean all of the machine parts with potable water, hot water then purified water.
[][]Soak with a clean dried lint free cloth to remove the water from the machine parts.
[][]Affix the clean label on the filling machine as ‘CLEANED’.

Annexure:

Annexure I Equipment Use Log Book

Dialysis Fluid Filling Machine set up, operation and cleaning Read More »