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Back to Basics
(FOI Releasable 10/6/2003)
(301) 827-3031
DARIUS@CBER.FDA.GOV
Overview
Regulatory Toolbox
Applicable Documents and Links
Regulatory Toolbox
Barr Decision
United States v. Barr Laboratories, Inc.
February 4, 1993, Decided
Civil Action No. 92-1744
812 F. Supp. 458; 1993 U.S. Dist. LEXIS 1932
www.gmp1st.com/barr1.htm
Includes discussion on:
9 Failures & Failure Investigations;
9 Sampling Sites and Sizes;
9 Cleaning & Methods Validations;
9 Mixing Times; and
9 Much, Much More
War Stories
War Stories
Equipment Suitability
(Suitability for Intended Use)
Spalling of silicone tubing used during
purification process.
Suitability studies not performed with solvent
system prior to determining acceptability for
intended use.
Impact on tubing of lengthy processing times
not evaluated.
Silicone particulates found in final purified
bulk.
HVAC Systems
Inability to balance rooms in classified
areas during OQ. Construction staff
added additional supply line to
supervisors office which was not accounted
for in the design specifications.
Pressure inversions of environmentally
classified areas (filling to capping areas).
HEPA Filters
SOP for integrity testing (performed by
contractor) not approved, nor available inhouse.
No specification to perform smoke studies
after repairs to HEPAs in Class 100 areas
have been made.
No specified life-spans for the HEPA filters.
Isolator Design
Plywood mock-up model of isolators
Verifies suitability of design geometries.
Allows staff to try unit prior to construction of
actual unit and offer recommendations for changes.
Isolators
Environmental classification surrounding
isolator.
Purpose of the isolator:
Total or Negligible Containment.
Live viral processing or sterility testing.
Isolator Observations
Operator standing on stool to reach half-suite fell
during sterility test, damaging isolator.
No method to remove accumulated empty vials
from inside isolator after a five-day filling
operation. Vials blocked air return grills.
Paper edged HEPA filters installed, which
deteriorated after several VHP sterilization cycles.
HEPA filter integrity testing not performed after
unit was installed.
Equipment/Vial Washers
Improperly balanced washer spray arm
scratched internal stainless steel surface of
washer, resulting in stainless steel
particulates in final product.
Spray coverage studies performed as part of
FAT were not available, nor included in
validation package.
Equipment/Vial Washers
Filters installed in WFI fluid path on vial
washer. Microbial growth noted in filters.
Fiber and glue accumulated in equipment
washer from paper labels, resulting in fibers
and particulates in bulk and final product.
No evaluation for cleanliness of internal
surfaces performed prior to use.
Autoclaves
Incorrect Hz (50 v. 60) solenoid installed on
autoclave, resulting in delivery of variable
sterilization times.
Integrity testing of sterilizing grade vent filters not
performed after removal.
Inadequate steam supply delivered, unable to
successfully validate.
Accumulation of debris in steam traps resulting in
inability to re-validate.
Autoclaves
Gravity v. Pre-Vacuum Pulse Units.
Drains not protected (screened) or cleaned post-use.
No preventative maintenance program. Cracked
gaskets noted.
Physical
Bugs
Variable Type
Independent
(Controlled)
Dependent
(Outcome)
Variables
Fo
Proof
Variables were
controlled
Kill
Evidence (that
process objectives
were met)
Indirect
Direct
Media Fills
Do not remove filled vials for weight checks or inprocess testing culling vials.
The intent of a media fill is to demonstrate the ability to
aseptically fill the product, not validate weight checks
or fill volumes, which should be done during OQ.
Removal of filled units diminishes the power of a media fill.
Non-integral (damaged) filled vials should be documented &
removed prior to incubation.
When non-integral vials are found during incubation and
exhibit growth, the organism/s should be identified,
documented and investigated.
Do not use filled units for Growth Promotion testing prior to
conclusion of incubation.
Media Fills
Not capturing first flush of media through
lines.
Inert gas (nitrogen) used during media fills.
Residual moisture (water) in sterilized
tubing of filling lines.
Define the number of units to be filled and
incubate that number of units.
Filling Equipment
Inability to validate a time/pressure filling system
due to vibrations from nearby railway tracks.
Weight dosage system installed after unsuccessful
validations.
Remote Particle Counters:
Tubing length exceeded manufacturers
recommendation.
Samplers not covered during sanitization of filling line,
resulting in damage to laser/mirror units.
Filling Equipment
Filling line barrier frames not grounded, causing
static discharge resulting in particulate excursions.
Accumulator table too close to wall. High volume
of personnel movement over open vials
interrupting first flush HEPA filtered air.
Stopper hopper at waist height, not protected by
barrier, or microbially monitored.
Lyophilizers
No vent filter installed, vented to Class
100,000 area.
Lyophilizer loading door opens and
obstructs laminar flow curtained barrier.
Class 100 zone surrounding door broken
during loading.
Lyophilizer chamber & condenser not
cleaned or sterilized.
Lyophilizers
Clean chamber with WFI and alcohol and
validate or qualify cleaning procedure.
Monitor chamber and condenser for residual
products and cleaning agents (CIP v.
Manual Cleaning).
Remember that the longest time that a
product is exposed unstoppered is in the
lyophilizer, not the filling line.
Lyophilizers
Margin testing of allowable ramp rates
not evaluated during PQ studies.
Method to detect thermal transfer fluid
leaks (silicone, Lexsol).
Chamber leak rate testing (real v. virtual).
Preventative maintenance program.
Impellers
Sediment noted in filtered bulk product.
Testing revealed sediment to be composed of
tungsten & nickel.
Bottom mounted impeller contained a worn
tungsten carbide bearing.
Changed to a top mounted external impeller.
Bioreactors / Fermenters
To minimize contamination risk, consider
performing integrity testing of filters used to
supply buffers and media.
Consider utilizing block and bleed valves
on sample collection ports to minimize false
positives during microbial sampling.
Centrifuges
Typical Centrifuges cooled by:
Potable, purified, or reverse osmosis water
Glycol
Centrifuges
Sanitary design and have the diagrams
available in-house.
Perform periodic integrity testing of the
cooling jacket.
Rotor sanitization/sterilization and storage
conditions.
Vent Filters
Perform integrity testing before and after use.
Life-spans should be based on conditions of use
and historical data.
Establish conservative life-spans initially, then increase
them as data/comfort levels increase.
Back-Up Generators
Back-Up Generators
Preventative maintenance schedule
procedurally based and documented.
Periodic testing of the generators.
Risk-Based Approach
When you know your:
Product
Flow-path
Equipment and how it works
Potential in-process and process impurities
Validation studies and their weaknesses
Readily available technologies at your disposal
Parting Thoughts
Risk-based approach to validation, production, inprocess testing, and maintenance.
Know the process, equipment and human
capabilities.
System suitability
Process capabilities
Personnel and Training
Clear/detailed SOPs
No matter how hard you try, you cannot inspect quality into a
product
Parting Thoughts
Processes drift - Small changes over time
may result in significant changes in the
process and final product.
In-process and final release specifications
should be specific and narrow enough to
capture potential drift.
Validations and preventative maintenance
should assist in assuring that the process is in a
state of control.
Parting Thoughts
The most frequently issued observations
begin with:
There are no data available to support
Questions