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Cleaning Process:
Cleaning in Development
By Birgitte Holst
INTRODUCTION
PART I
DEVELOPMENT OF A CLEANING PROCESS
Timeliness
What is timely process understanding and timely development of
a cleaning process?
Understanding of a cleaning process should be documented as part of
the development report. Set aside time for the development of the cleaning
process as product development progresses.
Cleaning process understanding can imply almost as many preparing
for Good Manufacturing Practice (GMP) disciplines as traditional develop-
ment of drug product processes or API processes require, but the time
spent is a minimal fraction when invested at the right moment. When
developing a cleaning process, the process should be as effective, as
safe, as environmentally sound, and as cost-efficient, as possible.
The technology transfer of a product to the manufacturing plant should
encompass a cleaning process designed for manufacture: a robust and
scalable cleaning process.
The cleaning process in the manufacturing plant must support expecta-
tions from authorities as indicated in Reference 1: Food and Drug
Administration (FDA) Draft Guidance from 2005, Amended New Drug
Applications (ANDA) - Impurities in Drug Products:
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Birgitte Holst
Gathering Know-how
What kind of know-how is needed and what effort does it require?
You do not have to spend a lot of extra time and resources when
gathering know-how about the cleaning process, just remember to relate
the gained results from product development (e.g., regarding degradation,
stability, etc.) to the production and cleaning process residues in the
equipment.
Know-how and process understanding of the cleaning process
includes knowledge about:
Level of toxicity and potency (basis for establishment of Maximum
Allowed Carry-over (MACO)) and cleanability (basis for worst-case
evaluations) of :
Product residues
Degradation of products generated in the time lapse to cleaning
Degradation of products generated in the cleaning process
Impact on stability from carry-over of product residues, cleaning
agent, and degradation products (basis for establishment of
MACO)
Level of toxicity of the cleaning agent and residues from the
cleaning agent after the cleaning process (basis for establishment
of MACO)
Rationale for the:
Functionality and optimal concentration of the cleaning agent
Cleaning process sequences (e.g.: pre-rinse, alkaline wash,
rinse, acidic wash, rinse, drying)
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Birgitte Holst
PART II
CLEANING PERSPECTIVE FOR
CLINICAL TRIALS MANUFACTURE
In this section, some of the scientific rationales related to the tasks in
cleaning validation will be handled in the context of the effort needed for
documenting a clean surface in a pilot facility.
Once all the equipment in a pilot facility is qualified, the author has
found that the majority of the effort for defining a cleaning validation
should be performed at the desk, because it is important that everything
we do, or choose not to do, is justified with scientific rationales. These
rationales must be present prior to performing any test or study that will be
used to document the status for the equipment.
We seldom have identical plants with identical production schedules;
therefore, the arguing and risk assessment should be documented in an
individual cleaning rationale for the specific product and pilot facility in
question. Most of the arguments and risk assessment possibilities dis-
cussed below can enter into a cleaning validation rationale for a manufac-
turing plant as well as for a pilot facility.
Figure 1
Definitions
Term Definition
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Birgitte Holst
A Changing Environment
Cleaning processes and documentation of the equipments cleaning
status is a greater challenge in a pilot facility than in a manufacturing facility
because new products or changed products are introduced all the time.
Developing means that changes can happen from the production of
one batch to the production of the next batch of the same product. Such a
scenario can lead to a change in product residues before cleaning and the
carry-over of different residues in a campaign as illustrated in Figure 2.
In most phases, performing cleaning validation in process development
will not be appropriate because changes in the production process can
result in changes of residues.
As partly indicated in Figure 2, it is a fact that a cleaning process gen-
erates different impurities dependent upon the product residues, the actual
equipment, and the use patterns for the actual equipment.
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Birgitte Holst
not generate identical impurities and all relevant impurities might not have
been part of the preclinical batches (no toxicology study has implied the
impurities). That is one more very good reason for testing the cleaning
status of the equipment with validated test and analytical methods prior to
production of a clinical batch production. The test and analytical methods
must be validated in relation to the content in the equipment prior to the
cleaning process.
The challenge is to relate existing validated processes and methods to
new situations. The new situation might compromise the validated state of
the processes and methods. A sound and scientific cleaning rationale for
the new or changed product must account for whether or not the validated
state rules or a new or modified approach must be used.
Figure 2
Residue Carry-over: Changes in residues can provide changes in
carry-over despite manufacturing the same product in development
Residues
from
B
Figure 3
Illustration of a Scenario that Provides One Matrix of Carry-over to
Product B
Figure 4
Illustration of a Scenario Providing another Matrix of Carry-over
to Product B
Figure 5
Batch-to-batch Contamination Can Occur in a Campaign
Residues Residues
after after
clean clean
Figure 6
Downstream Contamination Is Possible when Equipment Is Shared
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Birgitte Holst
Figure 6
Downstream Contamination Is Possible when Equipment Is Shared
If the product is a final dosage form, you must, in addition, look at the
impact of the strength of the product.
Scenarios in a campaign
If the product is produced in a campaign with no changes in the
campaign that can affect the residues as indicated in Figure 5 and
Figure 6, perform appropriate verification and monitoring docu-
menting that batch-to-batch contamination is acceptable.
Figure 7
Next Product Contamination after Change-over
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Birgitte Holst
The new product should be defined with regard to the following attributes:
Composition
Solubility
Cleanability
Treatment regime
Potency
Toxicology
Allergenicity (e.g.: mammalian host cell proteins)
The rationale for evaluating that the initial, validated cleaning process
still applies, must also come from the use patterns of the equipment in the
production process:
Identical production processes regarding:
Process conditions: temperature, time, agitation, etc.
Mother liquor/content in the process stream
Time lapses
Possibilities or risks for upstream or downstream cross-contamination
Inactivation
In addition, the rationale can be built on process knowledge and on
an understanding of the ability of the cleaning process to inactivate the
product residues. Again, already performed degradation studies can
provide some science to this rationale.
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Birgitte Holst
care of these impurities. The rationale for not testing carry-over from the
cleaning process can be process knowledge and understanding.
If by-products from the production process and degradation products
from the cleaning process are shown to be identical and later purification
steps are designed and tested to remove the relevant level of impurities of
this origin, no validation or verification should be needed.
Contrary to this, special attention should be given to the final
production steps where no purification steps can remove any impurities.
The total amount of carry-over will contribute to the impurity profile of
the final products.
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Birgitte Holst
When the next product B is known, check that the data match the
worst-case approach:
If the new worst-case scenario is not present you are home safe
If the new worst-case scenario is present you must show a lower
carry-over of the previous product A
Documents
Compliance must be documented by adherence to acceptance criteria
derived from established MACO. How to comply must be planned either in
SOPs, verification, or validation protocols. Documentation for compliance
will then be found in trend reports, verification, or validation reports. If
verification studies are done three or more times, the verifications studies
might be presented with a conclusion as though it were a validation study.
Thereafter, the validated state for cleaning prior to change-over to next
product is in place and no further studies are needed.
CONCLUSION
Cleaning validation might apply in a pilot facility, but if the risk
assessment shows that cleaning validation studies in a campaign do not
provide higher quality to the product and cleaning validation only raises
the development costs, cleaning validation should not be done.
Validation of a cleaning process toward a specific product in a pilot
facility can be of limited value because the production process changes
concurrently with the development phases, other means, such as cleaning
verification and monitoring, may be sufficient. When change-over to next
product occurs, means other than cleaning validation can show that risk
to patient and product quality has been mitigated by a well performed
cleaning process.
The effort for control of a new product in a plant must be looked upon
in context of former assessments and former cleaning activities. Gather
know-how and reuse already gathered know-how. If a proper effort for the
cleaning process is invested in development, it can speed up the time to
market. In addition, an effort for gathering cleaning process understanding
in development is in-line with Process Analytical Technologies (PAT)
thinking.
Cleaning processes will continue to be a challenge with the same
velocity as the industry invents new products.
REFERENCES
1. FDA draft guidance, 2005: ANDAs: Impurities in Drug Products
2. Alfredo Canhoto, Ph.D. Wyeth BioPharma. A Novel Bench Scale Apparatus to Model
and Develop Biopharmaceutical Cleaning Procedures. Journal of Validation Technology,
Vol. 11, Nov. 2004.
3. Borer Chemie are using the method as part of proactive R&D of cleaning agents to cus-
tomers. http://www.borer.ch
4. ICH Q6B: Specifications: Test Procedures and Acceptance Criteria for Biotechnological /
Biological Products
5. ICH Q7A identical to EU GMP Part II: Basic Requirements for Active Substances used
as Starting Materials
6. EU GMP Annex 13: Manufacture of Investigational Medicinal Products
7. Rebecca Brewer, Dober Group, 1-800-323-4983, rbrewer@dober-group.com
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Birgitte Holst
ACKNOWLEDGEMENTS
Birgitte Holst has worked for Novo Nordisk for more than 20 years,
always with validation as a theme. Ms. Holsts main experience has been
gathered in the manufacture of aseptic products and biotech APIs.
Currently, she holds the position as manager for a corporate expert
team in validation that is serving as internal consultants. Ms. Holst holds
a M.Sc. in Pharmacy from The Danish University of Pharmaceutical
Science. She may be reached by telephone at +45 4444 8888 / + 45
3075 8019 or by email at: bho@novonordisk.com.
Originally published in the April 2006 issue of the Journal of GXP Compliance