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Abstract
The goal of conducting validation is to demonstrate that a process, when operated within established
limits, produces a product of consistent and specified quality with a high degree of assurance. Validation
of water treatment systems is necessary to obtain water with all desired quality attributes. This also
provides a framework to establish a total control over the process which monitors safety, efficacy and
ultimately, the process outcomes. The present overview is an attempt to discuss various aspects of
validation including different approaches, components of water treatment systems, equipment
qualifications, phases of performance testing, documentation and post-validation monitoring.
flow rate and water quality conditions [11,13]. minimal connections. Connection points need
to be smooth and should offer minimal space
Distillation stills to harbour bacteria. No-flow or low-flow of
water, particularly through water distribution
Distillation equipment is used to remove piping can be a cause of microbial
nearly all impurities from water which proliferation and development of a biofilm.
includes sodium, hardening compounds such Biofilm formation is affected by the surface
as calcium and magnesium, other dissolved topography and chemistry of piping system
solids (including iron and manganese), that varies for different materials of
fluoride and nitrate. When operated properly, construction. Dead legs in sanitary piping
it effectively inactivates various systems are areas of piping, generally
microorganisms such as bacteria, viruses, associated with an instrument sample valve
protozoan cysts, etc. It can also remove connection point, where the branch section of
many organic compounds, heavy metals, piping exceeds a defined length. Dead legs in
chlorine, chloramines and radionucleides. distribution piping provide a place for
Selection of a distillation unit should be based microbial growth, as they can cause no-flow
on analysis of various parameters of water. conditions. Therefore, stagnant areas should
Also, regular maintenance of the unit is a be minimised wherever possible in both
critical factor in maintaining its effectiveness sanitary and non-sanitary systems.
[14]. Recirculating loops keep the water circulating
through carbon filters, resin beds, RO units
Ozone and heat sterilants and storage tanks which are often equipped
with UV lights to curtail microbial count to as
Ozone is a very strong oxidising agent with low a level as possible [11,16].
powerful disinfecting properties and can be
easily removed from water by exposure to UV SPECIFICATIONS FOR VARIOUS GRADES
light. It is an effective bactericidal, viricidal, OF WATER
fungicidal as well as sporicidal agent in water
treatment systems. It directly attacks the USP has stipulated the specifications and
outer surfaces of microorganism and definitions of the various grades of water
destroys their cell walls and membranes. In suitable for pharmaceutical use. It classifies
contrast to other oxidants and disinfectants, pharmaceutical water as (i) purified water,
the use of ozone results in far fewer toxic used for the manufacture of oral preparations
disinfection byproducts. Its production rate and other formulations, and (ii) water for
can be controlled by process parameters in injection (WFI), used for injectables,
order to avoid incorrect dosing and to ensure parenterals and intravenous fluids. USP also
optimised efficiency. More commonly, heat is specifies that purified water and WFI must
also used to control microbial growth in water adhere to the Environmental Protection
treatment systems. While circulating through Agency’s (EPA’s) Part 141, National Interim
distribution loops, treated water is heated to Primary Drinking Water Regulations [2,11].
80 ºC in the storage tanks [15]. Various Table 2 presents the principal standards for
components, along with their desired features purified water and water for injection.
and/or functions generally used in water
treatment systems, are summarised in Table EQUIPMENT VALIDATION
1.
Validation of water treatment systems follows
Continuous flow, absence of dead legs the same basic sequence as does the
and biofilms validation of other pharmaceutical manufac-
turing equipment. It is necessary that the
Sanitary systems for pharmaceutical waters system should be checked and certified as
imply the use of smooth surfaces with properly installed, equipped and properly
Table 1: Summary of components employed in water treatment systems and their desired
features / functions
Ozone and Heat Sterilants Strong oxidizing agent, effective at low concentration.
Both are used as biocidal.
Table 2: Specified limits for purified water and water for injection
pH 5.0-7.0 5.0-7.0
cfu* = colony forming units; ppb** = parts per billions; EU*** = endotoxin units
functioning as per its design [11,17]. low and high ends of the
Equipment validation has the following steps: ranges.
• Verification of valves, controllers and flow
Installation qualification (IQ) rates.
• SOPs should be written to describe start
It is the process which ensures and proves up, shut down and sanitisation
that the system has been supplied and procedures.
installed correctly, and meets the • Sanitisation of holding tanks and
predetermined specifications of the users. It distribution parts of water treatment
usually involves the generation of an IQ systems including periodic regeneration
protocol, a test and inspection plan for the of resin beds.
system. All installation parameters must be
• Evaluating pumps for proper functioning
documented and certified prior to operational along with the replacement of any
qualification of the system. For an IQ of water defective valves or seals.
treatment system, the following would be
typical key elements [11]: Performance qualification (PQ)
• Utilities requiring verifications includes After each major component of the water
electricity, compressed air, steam and treatment system has been operationally
feed water. Each should be checked verified, the next step is performance
properly at the time of installation of qualification. This phase includes various
equipment for water treatment tests designed to verify the satisfactory
systems. performance of the system. It should be
• Calibration of all process controlling carried out using real process materials and
instruments according to written tests intended to demonstrate accurate and
procedures and certification that they reliable performance over the full range of
meet the specified tolerance limits for expected operating conditions. PQ is the
accuracy, precision, and also in terms stage which documents that the product
of selectivity or specificity. quality continuously and consistently meets
• Verify documentation on system the required specifications. The major
design specifications including objective of this step is to demonstrate that
materials data and calibration the system produces and maintains
certificates. recirculating water, which meets the
compendial requirements for purified water
Operational qualification (OQ) over a suitable time period [11,17].