Professional Documents
Culture Documents
Sterile
Slide 1 of 62
January 2006
Sterile Production
Objectives To review basic GMP requirements in the manufacture of sterile pharmaceutical products To review air classifications for activities related to the manufacture of sterile products To review the different types of sterilization methods To review quality assurance aspects in the manufacture and control of sterile products To consider current issues applicable in your country
Sterile | Slide 2 of 62 January 2006
Sterile Production
GMP Requirements for Sterile Products
Additional rather than replacement Specific points relating to minimizing risks of contamination
microbiological particulate matter pyrogen
Sterile
Slide 3 of 62
January 2006
Sterile Production
General Considerations Production in clean areas Appropriate standard of cleanliness Filtered air supplied Airlocks for entry Personnel and/or equipment Materials Separate areas for operations component preparation (containers and closures) product preparation, filling, sterilization, etc.
Sterile | Slide 4 of 62 January 2006
1.1 1-2
Sterile Production
Premises Design Avoid unnecessary entry of supervisors and control personnel Operations observed from outside In clean areas, all exposed surfaces: Smooth, impervious, unbroken Minimize shedding and accumulation of particles, microorganisms Permit cleaning and disinfection No uncleanable recesses, ledges, shelves, cupboards, equipment Sliding doors undesirable False ceilings sealed 9.1 9.6
Sterile | Slide 5 of 62 January 2006
Sterile Production
Premises
In clean areas, all exposed surfaces (2):
Proper installation of pipes and ducts, no recesses, no unsealed openings Sinks and drains avoided, and excluded in Grade A and B areas Where installed, design, location, maintenance Effective cleanable traps Air breaks preventing backflow Floor channels open and easily cleanable
9.6.
Sterile | Slide 6 of 62 January 2006
Sterile Production
Premises Changing rooms Designed as airlocks Effective flushing with filtered air Separate rooms for entry and exit desirable Hand washing facilities Interlocking system for doors Visual and/or audible warning system Use filtered air supply to maintain pressure cascade Pressure differential approximately 10 to 15 Pascales Zone of greatest risk immediate environment
Sterile | Slide 7 of 62 January 2006
9.7 9.9
Sterile Production
Premises Pathogenic, highly toxic, radioactive materials Pressure cascade may be different Decontamination procedures air, equipment, garments Qualification including airflow patterns No risk to the product Warning system to indicate failure in air supply Pressure indicators results regularly recorded Restricted access e.g. use of barriers
Sterile | Slide 8 of 62 January 2006
9.9 9.12
Sterile Production
Equipment Conveyer belts Effective sterilization of equipment Maintenance and repairs from outside the clean area If taken apart, resterilized before use Use clean instruments and tools Planned maintenance, validation and monitoring Equipment, air filtration systems, sterilizers, water 10.1 10.5 treatment systems
Sterile | Slide 9 of 62 January 2006
Sterile Production
Equipment Water treatment plants and distribution system Design, construction, maintenance Operation and design capacity Testing programme
Water for Injection (WFI) Produced, stored, distributed prevention of growth of microorganisms Constant circulation at temperature above 70, or not more than 4 degrees Celsius
Sterile | Slide 10 of 62 January 2006
10.6
Sterile Production
Environmental Monitoring - I
Microbiological
Sterile
Slide 11 of 62
January 2006
Sterile Production
Environmental Monitoring - II Physical Particulate matter Differential pressures Air changes, airflow patterns Clean-up time/recovery Filter integrity Temperature and relative humidity Airflow velocity
Sterile | Slide 12 of 62 January 2006
Sterile Production
Sanitation Frequent, thorough cleaning of areas necessary Written programme Regular monitoring to detect resistant strains of microorganisms Chemical disinfection Monitoring of disinfectants and detergents Dilutions Clean containers, stored for defined periods of time Sterilized before use, when used in Grade A or B areas
Sterile | Slide 13 of 62 January 2006
3.1 3.2
Sterile Production
Sanitation Monitoring of clean areas Monitoring of personnel and surfaces after critical operations Frequent monitoring in areas where aseptic operations are carried out Settle plates, volumetric air samples, surface sampling (swabs and contact plates) Sampling methods should not contaminate the area Results considered when batch release is done
Sterile | Slide 14 of 62 January 2006
3.3
Sterile Production
Sanitation
Limits of detection established Alert and action, and monitoring trends of air quality
Table 1. Limits for microbial contamination (Information only)
Grade Air sample (CFU/m3) Settle plates (90mm diameter) (CFU/4hours) A B C D
Sterile | Slide 15 of 62
3.4
<3 5 50 100
Sterile Production
Personnel Minimum number of personnel in clean areas Especially during aseptic processing Inspections and controls from outside Training to all including cleaning and maintenance staff Initial and regular Manufacturing, hygiene, microbiology Special cases Supervision in case of outside staff 8.1 8.3 Decontamination procedures (e.g. staff who worked with animal tissue materials)
Sterile | Slide 16 of 62 January 2006
Sterile Production
Personnel High standards of hygiene and cleanliness Periodic health checks No shedding of particles No introduction of microbiological hazards No outdoor clothing Changing and washing procedure No watches, jewellery and cosmetics
8.4 8.6
Sterile
Slide 17 of 62
January 2006
Sterile Production
Personnel Clothing of appropriate quality: Grade D hair, beard, moustache covered Protective clothing and shoes Grade C Hair, beard, moustache covered Single or 2-piece suit (covering wrists, high neck), shoes no fibres to be shed 8.7 Grade A and B Headgear, beard and moustache covered, masks, gloves No shedding of fibres, and retain particles shed by operators
Sterile | Slide 18 of 62 January 2006
Sterile Production
Personnel Outdoor clothing not in change rooms leading to grade B and C rooms Change at every working session, or once a day (if supportive data) Change gloves and masks at every working session Disinfect gloves during operations Washing of garments separate laundry facility No damage, and according to validated procedures
Sterile | Slide 19 of 62 January 2006
8.8 8.9
Sterile Production
Group session 1
You are asked to visit a factory producing the following product lines:
Injections in ampoules and vials, including insulin, vaccines and heat-stable pharmaceuticals Sterile eye ointment
Describe the type of facility you would expect to find List the typical rooms, their purpose and air classification
Sterile | Slide 20 of 62 January 2006
Sterile Production
Possible Issues Poor design of the building Poor design of the systems, e.g. water, HVAC Flow of personnel Flow of material No validation or qualification Old facilities not complying with current requirements
Sterile
Slide 21 of 62
January 2006
Sterile Production
Possible Issues (continued)
Particulate levels/microorganisms Differential pressures Air changes Temperature/humidity
Sterile
Slide 22 of 62
January 2006
Sterile Production
Two categories of manufacturing operations:
Terminally sterilized
prepared, filled and sterilized
Aseptic preparation
some or all stages
1.3
Sterile | Slide 23 of 62 January 2006
Sterile Production
Manufacture of sterile preparations Classification of clean areas Manufacturing operation in an appropriate environment cleanliness level Minimize risks particulate and microbiological contamination product and material Meet classification "at rest" (i.e. "completed installation, equipment installed and operating, but no operating personnel present").
4.1
Sterile | Slide 24 of 62 January 2006
Sterile Production
Manufacture of sterile preparations For sterile pharmaceutical preparations: Grade A Local zone, high risk operations, e.g. filling, aseptic connections Usually UDAF systems used Grade B Background environment to grade A (in case of aseptic preparation and filling) Grade C and Grade D Clean areas for less critical operations
Sterile | Slide 25 of 62 January 2006
4.1
Sterile Production
Air Classification System
Grade At rest maximum permitted number of particles/m3 0.5 - 5.0 m A B C D 3 500 3 500 350 000 3 500 000 > 5 m 0 0 2 000 20 000 0.5 - 5.0 m 3 500 350 000 3 500 000 not defined >5 0 2 000 20 000 not defined In operation
3.1
Sterile
Slide 26 of 62
January 2006
Sterile Production
Manufacture of sterile preparations To reach Grade B, C and D, the number of air changes should be appropriate to the size of the area, number of personnel, equipment present Minimum of 20 air changes per hour Clean up time about 15-20 minutes Good airflow pattern in the area HEPA-filtered air Suitable methods to determine particulate matter and micro e.g. EU, ISO, Japan, USA 4.1 4.2.
Sterile | Slide 27 of 62 January 2006
Sterile Production
Manufacture of sterile preparations Control particulate during operation Monitoring during operation Alert and action limits for particulate and micro Action taken when exceeded Area grades should be proven (e.g. validation runs, media fills, environment, time limits based on microbiological contamination/bioburden found)
4.3 4.5
Sterile
Slide 28 of 62
January 2006
Sterile Production
Airborne particulate classification
US Customary Class 100 Class 100 Class 10 000 Class 100 000
4.1
Sterile
Slide 29 of 62
January 2006
Sterile Production
Processing Minimise contamination all stages including before sterilization and during processing No unsuitable materials, e.g. live microbiological organisms Minimize activities staff movement controlled and methodical avoid shedding of particles Temperature and humidity comfortable Containers and materials in the area
Sterile | Slide 30 of 62 January 2006
Sterile Production
Processing Validation should not compromise the processes Aseptic process validation: Sterile media fill (broth fills) Simulate actual operation intimate as closely as possible Simulate worst expected condition Use appropriate medium/media Sufficient number of units - e.g. equal to batch size (small batches) acceptable limit investigations Revalidation: periodic and after change New processing procedures validated Revalidation after significant changes And regular intervals
Sterile | Slide 31 of 62 January 2006
Sterile Production
Processing Water sources, water treatment systems and treated water Monitored regularly Chemicals Biological contamination Endotoxin Water specification Records of results and action taken
Sterile | Slide 32 of 62 January 2006
4.19
Sterile Production
Processing Components, bulk product containers and equipment fibre generation no recontamination after final cleaning stage properly identified sterilized when used in aseptic areas Used in clean areas, passed through double-ended sterilizers or use triple wrapping 4.22 4.23 Gas used to purge solution or blanket a product passed through a sterilizing filter
Sterile | Slide 33 of 62 January 2006
Sterile Production
Processing Bioburden monitored Products: Before sterilization Working limits established Solutions to be filtered before filling (especially LVP) Pressure release outlets hydrophobic microbiological air filters Starting materials microbiological contamination should be minimal Monitored as per specification
Sterile | Slide 34 of 62 January 2006
4.26, 5.3
Sterile Production
Processing Time intervals: Components, bulk containers, equipment Washing and drying and sterilization; and sterilization and use As short as possible Time limit validated Time intervals: Product Start of preparation of solution and sterilization (filtration) As short as possible Maximum time set for each product
4.23 - 4.24
Sterile | Slide 35 of 62 January 2006
Sterile Production
Group session 2 Considering the same factory as in the previous group session, discuss the process of sterilization. List all the items that will need to be sterilized (and indicate the choice of sterilization process). What are the key features you should find in each sterilization situation? Discuss the relevance, need, and the extent of qualification and validation required.
Sterile
Slide 36 of 62
January 2006
Sterile Production
Possible Issues Autoclave - no pressure gauge Autoclave - no temperature recorder Autoclave - superheated steam Clean room - pressure differentials Exposure for settle plates Interlocks turned off Rusty Laminar airflow cabinets HEPA filters not checked regularly
Sterile | Slide 37 of 62 January 2006
Sterile Production
Sterilization
Methods of sterilization:
Moist or dry heat Irradiation (ionizing radiation) Sterilizing gaseous agents (e.g. ethylene oxide) Filtration with subsequent aseptic filling
Whenever possible: Terminal sterilization by heat in their final container - method of choice
5.1 5. 2
Sterile | Slide 38 of 62 January 2006
Sterile Production
Sterilization Validation All sterilization processes Special attention when non-pharmacopoeia methods are used Non-aqueous or oily solutions Before the method is adopted its suitability and efficacy demonstrated with desired conditions: All parts of the load Each type of load Physical measurements and biological indicators (where appropriate) Verified at least annually and after change Records maintained
Sterile | Slide 39 of 62 January 2006
5.4 5.5
Sterile Production
Sterilization
For effective sterilization: Whole of the material subjected to the treatment Biological indicators: Additional method of monitoring Storage and use, quality checked through positive control Risk of contamination
Sterile | Slide 40 of 62 January 2006
5.6 - 5.7
Sterile Production
Sterilization
Differentiation between sterilized and not-yet-sterilized products Each basket/tray or other carrier, properly labelled
Name of material Batch number Sterilization status
Use of autoclave tape Sterilization records for each run approved as part of 5.8 - 5.9 the batch release procedure
Sterile | Slide 41 of 62 January 2006
Sterile Production
Terminal Sterilization
Sterilization by heat Sterilization by moist heat Sterilization by dry heat Sterilization by radiation Sterilization by gases and fumigants
6
Sterile | Slide 42 of 62 January 2006
Sterile Production
Terminal Sterilization Sterilization by heat Recording of each cycle, e.g. time and temperature chart Temperature: validated coolest part Check from second independent probe Additional chemical or biological indicators Heating phase: Sufficient time for the whole load Determined for each load Cooling phase: After sterilization cycle Precautions to prevent contamination Sterilized cooling fluid/gas
Sterile | Slide 43 of 62 January 2006
6.2 6.3
Sterile Production
Terminal Sterilization Sterilization by moist heat (heating in an autoclave) Water-wetable materials only, and aqueous formulations Temperature, time and pressure monitored Temperature recorder independent of the controller Independent temperature indicator Drain temperature recorded from this position Regular leak test when vacuum is part of the cycle Material allows for removal of air and penetration of steam All parts of the load in contact with steam Quality of the steam no contamination
Sterile | Slide 44 of 62 January 2006
6.4 6.6
Sterile Production
Terminal Sterilization Sterilization by dry heat For non-aqueous liquids, dry powders Air circulation in the chamber Positive pressure in chamber to prevent entry of non-sterile air HEPA filtered air supplied When removing pyrogens, challenge tests validation (using endotoxins)
6.7
Sterile | Slide 45 of 62 January 2006
Sterile Production
Terminal Sterilization Sterilization by radiation Suitable for heat-sensitive materials and products confirm suitability of method for material ultraviolet irradiation not acceptable Contracting service ensure validation status, responsibilities Measurement of dose during procedure Dosimeters independent of dose rate quantitative measurement number, location and calibration time-limit Biological indicators only as additional control Radiation sensitive colour discs
Sterile | Slide 46 of 62 January 2006
6.8 6.10
Sterile Production
Terminal Sterilization
Sterilization by radiation (2) Information forms part of the batch record Validation to cover effects of variation in density of
packages
Handling procedures to prevent misidentification of irradiated and non-irradiated materials Each package to have a radiation-sensitive indicator Total radiation dose administered within a predetermined period of time 6.10 6.13
Sterile | Slide 47 of 62 January 2006
Sterile Production
Terminal Sterilization Sterilization by gases and fumigants Only when no other method is suitable e.g. ethylene oxide, hydrogen peroxide vapour Validation: Also prove the gas has no damaging effect on product Time and conditions for degassing (specified limits) - residue Direct contact with microbial cells essential Nature and quantity of packaging materials Humidity and temperature equilibrium Monitoring of each cycle with biological indicators time, pressure temperature, humidity and gas concentration
Sterile | Slide 48 of 62 January 2006
6.14 6.20
Sterile Production
Terminal Sterilization
Sterilization by gases and fumigants (2)
Sterile Production
Terminally sterilized products
Grade D Preparation Components and product Remark Ensure low microbial and particulate count e.g. product actively supports microbial growth, or is held for a long period of time before sterilization, or is not prepared mainly in closed containers -
4.6 4.7
Sterile | Slide 50 of 62 January 2006
Sterile Production
Terminally sterilized products
Grade A in C background Preparation Filling before sterilization if product at unusual risk of contamination from environment Preparation and filling Remark e.g. slow filling operation, or Wide neck containers, or Exposure for a few seconds before sealing Ointments, creams, suspensions, emulsions
4.8 4.9
Sterile
Slide 51 of 62
January 2006
Sterile Production
Aseptic processing and sterilization by filtration
Aseptic processing Objective is to maintain the sterility of a product, assembled from sterile components Operating conditions so as to prevent microbial contamination What do you think are the aspects that require careful attention? 7.1 7.2
Sterile | Slide 52 of 62 January 2006
Sterile Production
Aseptic processing and sterilization by filtration Aseptic processing (2) Careful attention to: Environment Personnel Critical surfaces Container/closure sterilization Transfer procedures Maximum holding period before filling
Sterile | Slide 53 of 62 January 2006
7.3
Sterile Production
Aseptic preparation
Grade D C Preparation Components after washing Preparation of solutions to be sterile filtered later in the process Preparation and filling of sterile ointments, creams, suspensions, emulsions Remark
A (in B background)
Sterile
Slide 54 of 62
January 2006
Sterile Production
Aseptic preparation
Grade A (in B background) Preparation Sterile starting materials and components Remark (Unless subjected to sterilization or filtration through a microorganism retaining filter later in the process)
Preparation of solutions (if not to be sterile filtered later) Handling and filling of aseptically prepared products, Handling of exposed sterile equipment Transfer of partially closed containers, before complete stoppering
January 2006
4.10 4.13
Sterile Production
Sterilization by filtration Through a sterile filter of 0,22 m or less, into previously sterilized containers remove bacteria and moulds not all viruses or mycoplasmas Consider complementing with some degree of heat treatment Double filter layer or second filtration advisable, just before filling - no fibre shedding or asbestos filters Filter integrity testing immediately after use also before use if possible
7.4 7.7
Sterile | Slide 56 of 62 January 2006
Sterile Production
Sterilization by Filtration (2)
Validation to include
Time taken to filter a known volume Pressure difference to be used across the filter
Significant differences to be noted and investigated, recorded in batch records Integrity of gas and air vent filters checked after use, other filters at appropriate intervals
7.7
Sterile | Slide 57 of 62 January 2006
Sterile Production
Sterilization by Filtration (3)
Same filter not used for more than one working day, unless validated No filter interaction with product, e.g.
removal of ingredients releasing substances into product
7.8 7.9
Sterile | Slide 58 of 62 January 2006
Sterile Production
Quality Control Samples for sterility testing should be representative From parts of the batch, most at risk Aseptic filling at beginning and end of batch filling, and after interruptions Heat sterilized coolest part of the load Sterility of the batch ensured through validation Validated sterilization cycle Media fill Sterility test procedure as per pharmacopoeia, and validated for each2.1 -2.2 product Batch processing records, sterility testing records, environmental records should be reviewed
Sterile
Slide 59 of 62
January 2006
Sterile Production
Quality Control
Endotoxin testing for injectable products
Water for injection, intermediate and finished product
Always for large volume infusion solutions Pharmacopoeia method, validated for each product Failure of the test investigation Corrective action
Sterile | Slide 60 of 62 January 2006
2.3
Sterile Production
Finishing of products Containers closed by means of validated methods Samples checked for integrity Maintenance of vacuum (where applicable) checked Parenteral products inspected individually Visual inspection under suitable and controlled conditions: illumination and background eyesight checks of operators allowed frequent breaks Other methods: validated, and equipment performance checked at intervals results recorded
Sterile | Slide 61 of 62 January 2006
11.1 11.3
Sterile Production
Group session 3
Considering the same factory as in the previous group sessions, devise a plan for monitoring of the facility. List the parameters to be tested, tests to be used, acceptance criteria and frequency of testing.
Sterile
Slide 62 of 62
January 2006