sop for cleaning validation protocol tablet manufacturing equipment

 

cleaning validation protocol tablet manufacturing equipment

Scope of validation Tablet Manufacturing Equipment
Document No.
Supersede No.
Effective Date

 

1.0 PROTOCOL APPROVAL:
1.1 This protocol is prepared by

 

Department Quality Assurance
Signature

 

Name
Designation
Date

1.2 This protocol is reviewed by

Department Quality Assurance Quality Control Production Engineering
Signature

 

Name
Designation
Date

1.3 This protocol is approved by

Signature

 

Name
Designation
Date

 

2.0 TABLE OF CONTENT:

SR.

NO.

CONTENT PAGE

NO.

1.0 PROTOCOL APPROVAL
2.0 TABLE OF CONTENT
3.0 OBJECTIVE
4.0 SCOPE
5.0 RESPONSIBILITIES
6.0 INTRODUCTION OF CLEANING VALIDATION
7.0 CLEANING PROCESS DESCRIPTION
7.1 Brief description of the manufacturing process and processing equipment
7.2 Review of cleaning document and cleaning procedure
7.3 Equipment evaluation data for Select product
7.4 Selection of worst case product for cleaning validation study
8.0 METHODOLOGY OF CLEANING PROCESS VALIDATION
8.1 Sampling plan & Sampling Location
8.2 Acceptance Criteria
8.3 Maximum allowable carryover
8.4 Recovery study
8.5 Analytical Method Validation (Laboratory procedures and its rationale)
8.6 Sampling Technique
8.7 Swab sampling and analysis technique
8.8 Rinse sampling and analysis technique
8.9 Visual Inspection technique
8.10 Un-Cleaned equipment hold time
8.11 Cleaned equipment hold time
10.0 FAILURE INVESTIGATION AND CORRECTIVE ACTION
11.0 DOCUMENTATION
12.0 REVALIDATION
13.0 CONCLUSION
14.0 REFERENCE




3.0 OBJECTIVE:
The objective of this protocol is to define approach to validation of cleaning procedures for tablet manufacturing, and Packing . In addition to assure that there is no risk associated with cross-contamination of active ingredients.

4.0 SCOPE:
This protocol is applicable to validate the cleaning procedure of equipment used for the manufacturing and Packing of Tablet.

5.0 RESPONSIBILITIES:



5.1 Quality Assurance department shall be responsible for
5.1.1 Preparation of protocol.
5.1.2 Scheduling & conducting of validation
5.1.3 Monitoring of protocol completeness, accuracy, technical excellence and applicability
5.1.4 Data compilation and review the data/report
5.1.5 Validation reports preparation and recommendation thereafter (if required)
5.1.6 Approval of validation protocol

5.2 Production department shall be responsible for
5.2.1 To provide all applicable cleaning and operational procedures and documentation necessary for the generation of this protocol
5.2.2 To release equipment and accessories for validation
5.2.3 To provide personnel to assist in the preparation and execution of this protocol
5.2.4 Review the protocol and report.

5.3 Quality Control department shall be responsible for
5.3.1 To provide all applicable methodologies, analytical procedures and documentation necessary for generation and execution of this protocol.
5.3.2 All collected samples received from QA and analysis as per sampling plan.
5.3.3 To compile the analytical data.
5.3.4 To provide personnel to assist in the preparation and execution of this protocol.
5.3.5 Review the protocol and report.

5.4 Engineering department shall be responsible for
5.4.1 To provide all equipment contact surface area.
5.4.2 To provide the utilities for CIP and manual cleaning.
5.4.3 Review the protocol and report.

6.0 INTRODUCTION OF CLEANING VALIDATION:
This cleaning validation is to verify the effectiveness and consistency of the cleaning procedure for removal of product residues, preservatives, Excipients and/or cleaning agents as well as the control of potential microbial contaminants in product Selection of “Worst case” product on the basis of toxicity, solubility and Pharmacological action (Potency) of Active pharmaceutical Ingredients (API). if required the grouping approach for the equipment can be considered in the cleaning validation. Three consecutive applications of the cleaning procedure shall be performed during cleaning validation to justified effectiveness & reproducibility of the cleaning.
If any product introduced or discontinue into the line then revise the product matrix and perform cleaning validation accordingly if get any change in ‘Worst case’.

7.0 CLEANING PROCESS DESCRIPTION
7.1 Brief description of the cleaning process and processing equipment :
Manufacturing:- As per SOP
Compression:- As per SOP.
Coating:- As per SOP .
Packing:- followed by carton and corrugated Box Pack.

7.1.1 Process equipment : The equipment used in the processing and with direct contact to the
product



7.2 Review of Cleaning Documents & Cleaning procedure :

7.2.1 List of equipment to be cleaned & rationale :
This protocol will address the cleaning of the following product contact equipment used to manufacture the Carvit Tablet.

Sr. No. Sop No. Title Effective date Equipment Criticality Rating
1 Operation & Cleaning Procedure of Vibro Sifter Vibro Sifter Critical
02 Operation & Cleaning Procedure of Rapid Mixer Granulator Rapid Mixer Granulator Critical
03 Operation & Cleaning Procedure of  FBD Fluid Bed Dryer Critical
04 Operation & Cleaning Procedure of  Co-Mill Co-Mill Critical
05 Operation & Cleaning Procedure of  Bin Blender Bin Blender Critical
06 Operation & Cleaning Procedure of  Co-Mill Compression 35 Station Critical
07 Operation & Cleaning Procedure of  De-duster De-duster Critical
08 Operation & Cleaning Procedure of  Metal Detector Metal Detector Critical
09 Operation & Cleaning Procedure of  Coating Pan Coating Pan Critical
10 Operation & Cleaning Procedure of  Tablet Inspection Tablet Inspection Critical
11 Operation & Cleaning Procedure of  Blister Packing Machine Blister Packing Machine Critical

7.2.2 List of contact parts which are directly contact with the product during manufacturing

Sr. No. Equipment Name Equipment ID Contact parts
1 Vibro Sifter Lid & Sieve
2 Rapid Mixer Granulator Bowl, Flange, Chopper, Impeller
3 Fluid Bed Dryer FBD Bowl, FBD Bag
4 Co-Mill Hopper, Blade & Shaft
5 Bin Blender Lid  & Vessel, Blade
6 Compression 35 Station Hopper, Die & Punch Fid Frame & Chutes
7 De-duster Lid  & Mess
8 Metal Detector Acrylic Feed Frame
9 Coating Pan Coating Pan
10 Tablet Inspection SS Feed hopper
11 Blister Packing Machine Hopper & Chute

 

 

7.2.3 Cleaning Procedure:
7.2.3.1 Manual Cleaning Process:
The cleaning procedure as per reference SOP No. given in point 7.2.1 provides details of the procedure ,equipment and material; is required in order to conduct manual cleaning of the product manufacturing process equipments.

7.2.4 Holding Times:

Sr. No. Equipment name Un cleaned Equipment Hold time Cleaned Equipment hold time
1 Vibro Sifter Minimum 30 hr Minimum  72 hr
2 Rapid Mixer Granulator Minimum 30 hr Minimum  72 hr
3 Fluid Bed Dryer Minimum 30 hr Minimum  72 hr
4 Co-Mill Minimum 30 hr Minimum  72 hr
5 Bin Blender Minimum 30 hr Minimum  72 hr
6 Compression 35 Station Minimum 30 hr Minimum  72 hr
7 De-duster Minimum 30 hr Minimum  72 hr
8 Metal Detector Minimum 30 hr Minimum  72 hr
9 Coating Pan Minimum 30 hr Minimum  72 hr
10 Tablet Inspection Minimum 30 hr Minimum  72 hr
11 Blister Packing Machine Minimum 30 hr Minimum  72 hr

7.3 Equipment evaluation (Surface area) data:

Sr. No. Equipment Make Equipment ID Material of Construction Surface area

(square inch)

1 Vibro Sifter Techx Process Automation SS 316
2 Rapid Mixer Granulator Techx Process Automation SS 316
3 Fluid Bed Dryer Alliance India SS 316
4 Co-Mill Techx Process Automation SS 316
5 Bin Blender Techx Process Automation SS 316
6 Compression 35 Station Cadmach Machines SS 316
7 De-duster Techx Process Automation SS 316
8 Metal Detector NA SS 316
9 Coating Pan Mixo Fill SS 316
10 Tablet Inspection Propack SS 316
11 Blister Packing Machine NA SS 316
                                                                                                                 Total

7.4 Selection of worst case product for cleaning validation study
The ‘worst-Case’ product has been determined on the basis of toxicity, solubility, and Pharmacological action (Potency).

SR.NO PRODUCT  NAME GENERIC NAME ACTIVE PHARMACEUTICAL INGREDIENT (API) Potency mg per tablet

 

 

Solubility in water Toxicity (mg/kg) B.Size

(Tablets)

 

 

1 Levocetrizine Dihydrochloride Tablet Each tablet Contains:                            Levocetrizine Dihydrochloride IP 5 mg Levocetrizine Dihydrochloride 5 mg Freely Soluble 1,00,000
2 Calcium Carbonate  Calcitriol  & Zinc Sulphate Tablet

 

Each Film Coated Tablets Contains Calcium Carbonate     IP   625 mg Eq. to Elemental Calcium 250 mg Zinc Suplhate Mono. USP20.6 mg Eq. to Elemental Zinc  7.5 mg  Calcitriol   BP   0.25 mcg Elemental Calcium  250 mg

Elemental Zinc  7.5 mg

Calcitriol     0.25 mcg

Slightly Soluble

Very Soluble

In soluble

 

 

 

 

 

 

 

 

1,00,000
3 Calcium Carbonate Magnesium Hydrate,

Zinc Sulphate & Vit. D3  Tablet

Each Film Coated Tablet Contains Calcium Carbonate IP  1000 mg Magnesium Hydroxide IP 240 mg Zinc Sulphate Monohydrate   USP 11 mg   Vitamin D3   IP     200IU Calcium Carbonate  1000 mg

Magnesium Hydroxide  240 mg

Zinc Sulphate Monohydrate 11 mg   Vitamin D3   200IU

Slightly Soluble

Practically insoluble

Very Soluble

Practically insoluble

 

 

 

 

 

 

 

50,000
4 Paracetamol Tablet Each un Coated tablet Contains  Paracetamol IP 500 mg

 

Paracetamol  500 mg Sparingly soluble 2,00,000
5 Ciprofloxacin & Tinidazole Tablets Each Film Coated Tablet Contains Ciprofloxacin Hydrochloride Eq. to Ciprofloxacin 500 mg Tinidazole  IP 600 mg

 

Ciprofloxacin 500 mg

Tinidazole   600 mg

Soluble

Insoluble

 

 

 

50,000

Note:- 1) Based on the above data Carvit Tablet is become as “Worst Case” product hence it is considered in Cleaning Validation.

 

8.0 METHODOLOGY OF CLEANING PROCESS VALIDATION

When the process is completed then note the time and date step wise. Record the start of un cleaned hold time, after 30 hrs note the time with date for evaluation of un-cleaned hold time.
After 30 hr take swab and rinse sample for microbial evaluation as per respective SOP QM-047-02
Take the sample for un-cleaned hold time as per sampling plan given at page no. 30.
Clean all equipments as per respective SOP for all equipment given at point no. 7.2
Initially take the microbial swab as point no. 8.7 then Take rinse sample for chemical analysis as per point no. 8.8
After collection of samples hold all equipments and accessories for 72 hrs. After 72 hrs again collect the samples of all equipments and accessories as per sampling plan . After 72 hr. note the time and date as per sampling plan for evaluation of cleaned equipment hold time. First take swab sample for microbiology, then chemical rinse. Send these samples to QC for analysis.
Sample shall be taken from hardest to clean surface of the equipment(i.e Dead legs, Dead spots).
Continue the above procedure for another two batches.

8.1 SAMPLING PLAN AND SAMPLING LOCATION FOR MICROBIAL TESTING (HOLD TIME)

Sr. No. Equipment Sample Type Sample Location Sample Quantity

required

Sample ID Test Parameter Acceptance Criteria
1 Vibro Sifter Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
2 Rapid Mixer Granulator Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
3 Fluid Bed Dryer Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
4 Co-Mill Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
5 Bin Blender Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
6 Compression 35 Station Swab Compression NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
7 De-duster Swab Compression NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
8 Coating Pan Swab Inspection NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
9 Metal Detector Swab Coating NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
10 Tablet Inspection Swab Inspection NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
11 Blister Packing Machine Swab Packing NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil

 

8.1.1 SAMPLING PLAN AND SAMPLING LOCATION FOR CHEMICAL TESTING CLEANED EUIPMENT

Sr. No. Equipment Sample Type Sample Location Sample Quantity

required

Sample ID Test Parameter Acceptance Criteria
1 Vibro

Sifter

Rinse Granulation 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
2 Rapid Mixer Granulator Rinse Granulation 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
3 Fluid Bed Dryer Rinse Granulation 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
4 Co-Mill Rinse Granulation 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
5 Bin Blender Rinse Granulation 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
6 Compression 35 Station Swab Compression 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
7 De-duster Swab Compression NA pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
8 Coating Pan Swab Inspection NA  

 

pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
9 Metal Detector Rinse Coating 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
10 Tablet Inspection Swab Inspection NA pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb
11 Blister Packing Machine Swab Packing 100ml pH 5.0-7.5
Conductivity NMT 5.1 µS
TOC NMT 500ppb

8.1.2 SAMPLING PLAN AND SAMPLING LOCATION FOR MICROBIAL TESTING CLEANED EQUIPMENT

 

 

Sr. No. Equipment Sample Type Sample Location Sample Quantity

required

Sample ID Test Parameter Acceptance Criteria
1 Vibro

Sifter

Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
2 Rapid Mixer Granulator Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
3 Fluid Bed Dryer Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
4 Co-Mill Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
5 Bin Blender Swab Granulation NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
6 Compression 35 Station Swab Compression NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
7 De-duster Swab Compression NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
8 Metal Detector Swab Inspection NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
9 Coating Pan Swab Coating NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
10 Tablet Inspection Swab Inspection NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil
11 Blister Packing Machine Swab Packing NA Total Aerobic Count
Bacteria NMT100 cfu
Fungi Nil

8.2 ACCEPTANCE CRITERIA :
8.2.1 For cleaned equipment

For Chemical:
No more than 0.1% of the normal therapeutic dose of any product will appear in the maximum daily dose of the following product.
No more than 10 ppm of any product will appear in another product.
No quantity of residue should be visible on the equipment after cleaning procedures are performed. Spiking studies should determine the concentration at which most active ingredients are visible.
For microbial:
NMT100cfu / ml for rinse sample and NMT 100cfu /swab for swab sample.
8.2.2 For un-cleaned equipment

For microbial: For Information for rinse sample and swab sample.

8.3 Maximum Allowable Carryover:
Cleaning Limits Selection Criteria based on Maximum Allowable Carryover (MAC) :

8.3.1 MAC Based on 0.1 % Safety Factor

MAC = Lowest daily dose (mg) x Lowest B.Size (Kg) x 1000000
Largest Daily Dose (mg) x 1000

8.3.2 MAC based on 10 ppm = 0.00001mg

= 10 ppm x B.Size
= 0.00001 x 1808 x 1000000 = 18080 mg
Based on above criteria 1468 mg is the lowest value, hence it is consider as acceptance criteria.

8.3.3 MAC for each square inch.

MAC value =
Total surface area
(Equipments)

8.3.4 MAC for swab sample.



Surface area for swab sample 5”x 5” .
Total surface area in swab sample = 5 x5= 25 square inch.
MAC for each swab = MAC for each square inch x total surface area of swab
= 0.44 x 25 = 11 mg/swab
MAC for each swab = 11 mg/swab = NMT 1100µg/swab
8.3.5 MAC for rinse sample of each equipment.

 

 Sr. No. Equipment MAC/square inch (mg) Surface area

(square inch)

MAC (mg) MAC (µg)
1 Vibro Sifter
3 Rapid Mixer Granulator
3 Fluid Bed Dryer
4 Co-Mill
5 Bin Blender
6 Compression 35 Station
7 De-duster
8 Metal Detector
9 Coating Pan
10 Tablet Inspection
11 Blister Packing Machine Sr. No. Equipment MAC/square inch (mg) Surface area

(square inch) MAC (mg) MAC (µg)

1 Vibro Sifter

3 Rapid Mixer Granulator

3 Fluid Bed Dryer

4 Co-Mill

5 Bin Blender

6 Compression 35 Station

7 De-duster

8 Metal Detector

9 Coating Pan

10 Tablet Inspection

11 Blister Packing Machine

8. 4 Recovery study:

8.4.1 Recovery study shall be cover in Analytical method validation.
8.4.2 Perform analytical method validation and swab recovery studies. Spiking Studies for determining the concentration at which most active pharmaceutical ingredients.
8.4.3 Report the results applying the recovery factor for active pharmaceutical ingredients with consideration also taken for any chemical variants (active decomposition materials), write summary and conclusion. Record the recovery study .
8.4.4 ACCEPTANCE CRITERIA: Shall be Not Less than 80%.

8.5 Analytical Method Validation (Laboratory procedures and its rationale)

8.5.1 Analytical method to be used for cleaning validation shall be specific (i.e. either or combination of HPLC, TLC,) and validated for following parameters:
Specificity
Linearity
Limit of detection
Limit of quantification
8.5.2 Attach analytical method validation report.

8.6 Sampling technique :
There are two sampling technique :
8.6.1 Swab sample technique : This is direct surface technique use wet swab.
8.6.2 Rinse sample technique : This Technique is applicable where difficult to carry swab sample.
8.6.3 For uncleaned/cleaned equipment sample detail:
For microbial analysis: Purified water shall be use for microbial evaluation.
For chemical analysis : Purified water shall be used for swab & rinse sample.

8.7 Swab sampling and analysis technique



8.7.1 Take swab as per SOP NO
8.7.2 Select 5 square inch area of the surface and swab it by sterile cotton swab by dipping it in Peptone water tube test tube containing 2 ml Peptone water.
8.7.3 After swabbing , dip the swab in same peptone tube and shake it properly so as that it liberate adhered microbes into the Peptone water and immediately transfer it to microbiology department.
8.7.4 Add this 2 ml of activated peptone water to a sterile Petri dish and add approximately 20 ml of autoclaved media (Molten). Shake it and allow to solidify.
8.7.5 Incubate the plate at 20° C to 25° C for 72 hour. Then incubate the same plate at 30°C to 35°C for 48 hour for Bacterial Count.
8.7.6 Count the CFU of the plate and Record the observation in report.
8.6.1 Selection of Surface Area, using one side of moistened swab wipe the test surface of 5” x 5” with 10 firm horizontal strokes as illustrated in figure 1. Turn the swab stick over to its other side, wipe the test surface of 5” x 5” with 10 firm vertical strokes as illustrated in figure 2 . Wherever 5” x 5” area is not available for swab sampling, carry out sampling from hardest to clean area.
8.6.2 Wherever 5” X 5” is not available , carryout sample from hardest to clean area of the entire area .
8.6.3 At the end of the each stroke lift the swab carefully and keep the swab stick in the container.

 

8.8 Rinse sample and analysis technique

8.9.1 For Chemical:- Use Purified water and collect it into a container. Rinse the equipment & accessories from top to cover all areas of equipment and collect the 100 ml puriedfied water from drain point of equipment. Sample quantity 100ml shall be use for rinse.

8.10 Visual Inspection technique.

8.10.1 Inspect the cleaned equipment by using necessary visual aids (Torch, Lights, etc) while performing the inspection rather than peeping through the glass/ into the machine.
8.10.2 During inspection focus on hard –to- clean areas of the equipments.
8.10.3 Ensure complete dryness of the surface so that all cleaning solutions have been removed and there is no potential for residue formation after wards.

8.11 Un-cleaned equipment hold time

 

Stage Equipment Time and date of   manufacturing process completed   (T1) Time and date of before start of cleaning of equipment  (T2) Observed un cleaned hold time

(T2-T1)

Hold time  of un cleaned equipment. Minimum time (Hrs)
After completion of  process  and before cleaning Vibro Sifter 30 Hrs
Rapid Mixer Granulator 30 Hrs
Fluid Bed Dryer 30 Hrs
Co-Mill 30 Hrs
Bin Blender 30 Hrs
Compression 35 Station 30 Hrs
De-duster 30 Hrs
Coating Pan 30 Hrs
Tablet Inspection 30 Hrs
Metal Detector 30 Hrs
Blister Packing Machine 30 Hrs

 

 

 

8.12 Cleaned equipment hold time

Stage Equipment Time and date of cleaning process completed (T3) Time and date of hold time of cleaned equipment (T4) Observed cleaned hold time (T4-T3) Hold time of cleaned equipment. Minimum
After Cleaning Process Vibro Sifter 72 Hrs
Rapid Mixer Granulator 72 Hrs
Fluid Bed Dryer 72 Hrs
Co-Mill 72 Hrs
Bin Blender 72 Hrs
Compression 35 Station 72 Hrs
De-duster 72 Hrs
Coating Pan 72 Hrs
Tablet Inspection 72 Hrs
Metal Detector 72 Hrs
Blister Packing Machine 72 Hrs

 

10.0 FAILURE INVESTIGATION AND CORRECTIVE ACTION:

If result is comes out of limit then investigate the route cause . On the basis of investigation necessary corrective action shall be implemented. Again repeat the study on worst case for three consecutive run.

11.0 DOCUMENTATION:
11.1 After verifying visual cleanliness, record the observation in report.
11.2 After analyzing the Swab/Rinse samples, record the observation in report.

12.0 REVALIDATION :
12.1 Any major change in equipment
12.2 Any change in cleaning procedure.
12.3 Change in analytical procedure
12.4 Change in worst case.
12.5 Change in regulatory requirement
12.6 Change in site location.

13.0 CONCLUSION:
Provide the conclusion and recommendation on the basis of execution results of the cleaning validation protocol.

 

 

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