Ipqc for parenterals

1. 1

2. CONTENTS
Introduction to parenterals
What is IPQC
Importance of IPQC and test performed
IPQC tests for parenterals
Documentation of parenterals
Problems encountered and remedies

3. PARENTERALS
A parenteral dosage form can be defined as a sterile drug product which is
presented in the form of solution, suspension, emulsion, or reconstituted
lyophilized powder, suitable for administration by injection through skin or
mucous membrane.
Para enteron = beside the intestine.

4. Manufacturing of small volume parenterals
Market survey Projected sales
Planning and
Scheduling functions
personnel Documentation Equipment and
control facilities management
Material management
Preparation of facilities
Purchasing
Preparation equipment and packaging components

5. Manufacturing of products
Sterilization of products
Aseptic subdivision and sealing
Online testing
Capping/ outer sealing
Inspection
Quarantine
Finishing, labeling and packaging
warehouse
Market

6. QUALITY CONTROL
Quality itself has been defined as fundamentally relational: 'Quality is
the ongoing process of building and sustaining relationships by
assessing, anticipating, and fulfilling stated and implied needs.'
According to WHO
QC is part of GMP which is concerned with sampling, specification,
Testing and with the organization, documentation and release procedures which
ensures that the necessary and relevant tests are actually carried out and the
materials are not released for sale or supply until their quality has been judged to
be satisfactory
According to ISO 9000:
The operational techniques and activities that are used to fulfil the
requirements for quality.

7. IN PROCESS QUALITY CONTROL
 IPQC means controlling the procedures involved in manufacturing of the
dosage forms starting from raw materials purchase to dispatch of the quality
product in ideal packaging.
 It monitors all the features of the product that may effect its quality and
prevents errors during processing.
 It is the activity performed between QA and QC.
PURPOSE OF IPQC
 To ensure detectable and significant human errors.
 Equipment failure and idiosyncrasies.
 Abnormal interpretation.
 Adoption of given procedures.

8. Importance of IPQC
 To minimize human errors.
 Provides accurate, specific, and definite description of the procedure to be
employed.
 It is planned system to identify materials and equipment's processed and
operated.
 Used to detect errors if and when it does occur.
 Is to enforce the flow of manufacturing and packaging operations according
to established routes and practice.
IPQC TESTS
 These are the tests performed between QA and QC and provides for the
authorization of approved raw materials for manufacturing based on
actual laboratory testing generally called as IPQC such as physical,
chemical, microbiologic and biologic tests.

9. .
SCOPE
 In process quality control are particularly important where a process
may vary with time such as tablet weights, fill volume, head space
gases etc.
TYPES OF IPQC TESTS
Physical and
chemical.
Biologic and
microbiologic
IPQC Tests
Identity tests
Quality tests
Purity tests
Potency tests

10. Physical and chemical tests
Identity tests
These tests are qualitative chemical methods used to conform the actual
presence of compound for example color formation, precipitation.
Quality tests
These tests are the physical methods used to measure accurately the
characteristic properties of drug .
For example: Absorbance, refractive index.
Purity tests
Purity tests are designed to estimate the level of all known and significant
impurities and contaminants in the drug substance under evaluation .
For example: Tests for clarity of solutions, Acidity, Alkalinity.
Potency tests
Potency tests are assays that estimate the quantity of an active ingredient
in the drug.

11. Biologic and microbiologic testing
 It includes macro and micro biologic assays and tests for safety, toxicity,
pyrogenicity, sterility, antiseptic activity and antimicrobial preservative
effectiveness of tests.
 Biologic testing of drugs can be Qualitative / Quantitative in
nature.
 It utilizes intact animals , animal preparations, isolated living
tissue.
When are these tests employed
 Biologic methods employed in the following situations
 When adequate chemical assay has not been devised for drug substances
although its chemical structure has been established.
For example: Insulin
 When chemical structure of drug substance has not been fully elucidated.
For example: Parathyroid hormone.
 When drug is composed of substances of varying structure and activity
For example: Digitalis and posterior pituitary hormone.

12. IPQC for parenteral products
 Clarity test( for particulate matter )
By visual method
Coulter counter method
Light obscuration technique
 Leakage testing( package integrity)
Visual methods
Bubble test
Dye test
Vacuum ionization method
 For fill volume
 pH
 Pyrogen testing
Rabbit fever response test
Limulus amoebocyte lysate test
 Assay for drug content

13.  Sterility test
Membrane filtration method
Direct inoculation method
 Test for packing containers
For glass containers
Water attack test
Powder glass test
For plastic containers
Leakage test, collapsibility test, transparency test, water vapor
permeability test.
 Inspecting for label check
 Uniformity of contents
 Uniformity of weight.
 Passiability of parenteral preparation from needle
 Conductivity test

14. CLARITY TESTING (DETECTION OF PARTICULATE MATTER)
Particulate matter can be detected in parenteral product by two methods,
including visual inspection and electronic particulate counting.
A) Visual method
 In visual inspection, each injectable is inspected visually against white and
black backgrounds. The white background aids in detection of dark
colored particles.
 The light or reflective particles will appear against the black back ground.
Some visual-enhancing aids can increase the efficiency.
 A magnifying lens at 2.5 × magnification set at the eye level facilitates the
inspection. Microscopic examination enhances detection of particulate
matter in injectable. Visual inspection gives the qualitative estimation of
the particulate matter.
 Acceptance Standards is that each container checked must not contain
any visible particulate matter.

15. B) Automated techniques
 The automatic systems are also called as the electron particles counter.
the electronic particles counter evaluates the particles in injectables
automatically.
 However, this method requires destruction of the ampoule/container for
the particle examination.
 Electronic particles counting may be based on any one of the following
principles: a) change in electrical resistance, b) light blockages principle
and c) light scattering. Some of the automated systems for visual particle
inspection include Autoskan, Eisai Ampoule inspection machine, Schering
PDS/A-V system, etc. Autoskan System.
 The Autoskan system is based on light scattering principle whereby the
particle in the path of a light source causes the scattering of light. The
scattered light is measured and provides the corresponding information
regarding the presence of particulate in the sample. This is a non-destructive
test.

16. Based on change in the electrical resistance
Coulter counter technique
 Coulter Counter counts the particles in a sample based on the change in the
electrical resistance. Particle size detection limit in this instrument is from 0.1 to
1000 micrometer.
 The powder sample requires pretreatment such as dispersion in an electrolyte to
form a very dilute suspension.
 The Suspension is usually subjected to ultrasonic agitation to avoid particle
agglomerates.
 A dispersant may also be added to aid particle deagglomeration. Passage of
particle causes the change in electrical resistance in between the electrodes
which is proportional to the volume of particle.
 The change in resistance is converted into voltage pulse which is amplified and
processed electronically and split into the particle size distribution into many
different size-range.
 This is a destructive test and large errors in measuring flakes and fibers are
expected.
 This test is not recommended by FDA for parenteral.

17. Principle of light obscuration
 Tungsten lamp produces a constant collimated beam of light that pass
through a small rectangular passageway and impinges onto a
photodiode.
 Liquid can flow through the passageway between the light source and
photodiode.
 If a single particle transverses the light beam there results a reduction in
normal amount of light received by the photodiode .
 This reduction of light and the measurable decrease in the output from
the photodiode is proportional to the area of the particle interrupting the
light flow
 Thus light obscuration principle measures particle size based on
diameter of circle having equivalent area.

18. Test method
 Use a suitable apparatus based on the principle of light blockage
which allows an automatic determination of the size of particles and
the number of particles according to size.
Method
 Mix the contents of the sample by slowly inverting the container 20
times successively.
 If necessary, cautiously remove the sealing closure. Clean the outer
surfaces of the container opening using a jet of particle-free water and
remove the closure, avoiding any contamination of the contents.
Eliminate gas bubbles by appropriate measures such as allowing to
stand for 2 min or Sonicate.
 For large-volume parenterals, single units are tested.

19.  For small-volume parenterals less than 25 ml in volume, the contents
of 10 or more units is combined in a cleaned container to obtain a
volume of not less than 25 ml;
 Then 3 aliquots are prepared with about 5 ml sample and injected
into the sensor.
 the test solution may be prepared by mixing the contents of a suitable
number of vials and diluting to 25 ml with particle-free water or with an
appropriate particle-free solvent when particle-free water is not suitable.
 Small volume parenterals having a volume of 25 ml or more may be
tested individually.
 Remove three each of not less than 5 ml, and count the number of
particles equal to or greater than 10 μm and 25 μm.
 Disregard the result obtained for the first portion, and calculate the mean
number of particles for the preparation to be examined.

20. Principle of light scattering
 When a beam of light strikes a solid object three events occur some of the
light is absorbed some is transmitted rest is scattered.
 Scattered light is composite of diffracted, reflected, refracted light.
 Particle counters that operate on the basis of light scattering are designed
to measure the intensity of light scattered at fixed angles to the direction of
the light beam.
 As the liquid flows into a light sensing zone particles in the fluid scatter light
in all directions.
 The scattered light is directed onto system of elliptical mirrors that then
focus the light onto a photo detector.
 The photo detector converts the signals corresponding area/volume
diameter of the particle.

21. Acceptance criteria
 As per USP LVP : NMT 50 particles/ ml (size 10 or more than 10
micrometer) & 5 particles/ ml (size more than 25 micrometer)
 SVP: 10,000 particles/ container of size 10 micrometer or greater &
NMT 1000 particles/ container greater than 25 micrometer.

22. Leakage test
 Leakage test is employed to test the package integrity. Package integrity
reflects its ability to keep the product in and to keep potential
contamination out.
 It is because leakage occurs when a discontinuity exists in the wall of a
package that can allow the passage of gas under pressure or
concentration differential existing across the wall.
leak test methods.
A) VISUAL INSPECTION
 Visual inspection is the easiest leak test method to perform. But this method is
least sensitive..
 The method is used for the evaluation of large volume parenteral. To increase
the sensitivity of the method, the visual inspection of the sample container may
be coupled with the application of vacuum to make leakage more readily
observable.
 This method is simple and inexpensive. However, the method is insensitive,
operator dependent, and qualitative.
 Sometimes, the method is used in combination with pressure and /or
temperature cycling to accelerate leakage to improve sensitivity.

23. B) BUBBLE TEST
 The test package is submerged in liquids. A differential pressure is
applied on the container. The container is observed for bubbles.
 Sometimes, surfactant added liquid is used for immersion of test
package. Any leakage is evident after the application of differential
pressure as the generation of foaming in immersion liquid. The method is
simple and inexpensive.
 The location of the leaks can be observed in this method. However, it is
relatively insensitive and the findings are operator dependent and are
qualitative.
 The optimized conditions can be achieved using a surfactant immersion
fluid along with the dark background and High intensity lighting.
Generation of a differential positive pressure of 3 psi inside the vial and
observation of any leakage using magnifying glass within a maximum test
time of 15 minutes.
Positive leak test result. Air bubbles

24. C) DYE TESTS
 The test container is immersed in a dye bath. Vacuum and pressure is
applied for some time.
 The container is removed from the dye bath and washed. The container
is then inspected for the presence of dye either visually or by means of
UV spectroscopy.
 The dye used may be of blue, green, yellowish-green color.
 The dye test can be optimized by use of a surfactant and or a low
viscosity fluid in the dye solution to increase the capillary migration
through the pores.
 The dye test is widely accepted in industry and is approved in drug use.
The test is inexpensive and is requires no special equipment required
for visual dye detection.
 However, the test is qualitative, destructive and slow. The test is used
for ampoules and vials.

25. D) VACUUM IONIZATION TEST
 Vacuum ionization test is useful for testing leakage in the vials or bottles sealed
under vacuum.
 This test is used for online testing of the lyophilized products. High voltage, high
frequency field is applied to vials which to cause residual gas, if present to glow.
Glow intensity is the function of headspace vacuum level.
 The blue glow is the indicative of vacuum which indicates the absence of leak
while the purple glow indicative of no vacuum. The sensitivity of the method is
not documented. This test is on-line, rapid and is non destructive test.
 However, the proteins present in the test sample may be decomposed. This
method is used for the lyophilized vials of biopharmaceuticals.
528 × 904 - Leak Test Vacuum Systems

26. Check for fill volume
 After filling the containers they are checked for the
correct volume filling.
 Check for fill volume is by visual inspection.
 This is important for small volume parenterals where the volume
is less .
 By keeping the container against a bright background we can
check for the fill volume.
 After conforming for the correct fill volume then they are lacked
and labelled and sent to the ware house.

27. pH
 Checking the bulk solution, before filling for drug content,
pH, color, clarity and completeness of solution
 The pH of a formulation must be considered from following standpoint:
1) the effect on the body when the solution is administered
2) the effect on stability of the product
3) the effect on container-closure system
 pH measurement
pH is measured by using a pH meter .
pH meter is initially calibrated with respective buffer capsule then the pH
of the preparation is measured.

28. What are pyrogens
 The term pyrogen frequently refers to gram negative bacterial endotoxin.
 Pyrogen is a general term for any substance that causes fever after IV
administration / inhalation .
 Microbial substances which act as pyrogen includes bacteria , fungi ,
plasmodia , viruses, staphylococcal endotoxin.
 The amount of USP reference standard endotoxin needed to initiate
pyrogenicity in humans and rabbits is about 1ng/kg.
 Naturally occurring bacterial endotoxin contain the lipid, carbohydrate and
protein makeup of the outer cell membrane of gram negative bacteria.

29. Test for pyrogens can be carried out by in-vitro and in-vivo methods.
A) Rabbit test (in-vivo)
B) LAL test (Limulus amoebocyte lysate) (in-vitro)
A)RABBIT TEST:
Principle:
The test involves measurement of rise in body temperature of the rabbits following
the intravenous injection of a sterile solution of the substance to be tested.
The body temperature of the rabbits increases if pyrogens are present in the
injected test solution.
SELECTION OF TEST ANIMALS:
Healthy , adult rabbits of either sex, each weighing not less than 1.5kg.
Do not use any rabbit for main test if:
1) It shows a temperature variation greater than 0.20 c between two successive
readings noted during the determination of initial temperature .
2) And it’s temperature is higher than 39.80 c or lower than 380 c

30. EQUIPMENTS REQUIRED FOR THE TEST:
 All glass ware, syringes, 20 – 30 gauge needle is used and thermometer
must be thoroughly washed with water for injection and heated in a hot air
oven at 2500c for NLT 30 min.
 Retaining boxes for rabbits.
TEST:
The test is carried out on a group of three rabbits.
Procedure:
Preparation of the sample:
 Warm the solution to About 37 ± 2 o c before the injection. In the case of
lyophilized products dissolve it in normal saline solution.
Determination of initial temperature of rabbits:
 Insert a clinical thermometer into the rectum of each rabbit and normal readings of
body temperature are taken prior to the injection of test solution.
 Two such readings are taken at an interval of 30 minutes and the mean is
calculated.
 This mean reading is taken as the initial temperature of the rabbits or as a control.

31. Temperature recording
USP <85> states the following:
 Use accurate temperature sensing device such as clinical thermometer,
or thermistor probes or similar probes that have calibrated to assure an
accuracy of ±0.10c.
 Insert the temperature sensing probe into the rectum of the test rabbit to a
depth of not less than 7.5 cm .
 Thermocouple contains two dissimilar electric conductor wires joined at
one end to form measuring junction that produce thermal EMF.
 Thermocouples must be calibrated against National institute of standards
and technology.

32. Determination of the response of rabbits:
 The test solution is injected into the ear vein of each rabbit.
 The volume of injection is 10 ml/kg of the body weight.
 This volume varies according to the test substance and is prescribed
in the individual monograph.
 Record the temperature of each rabbit at an interval of 30 minutes for
3 hours after the injection.
 This is the maximum temperature recorded for that rabbit.
 The difference between maximum temperature and initial temperature
is taken as its response.
 If this difference is negative, it is taken as a zero response.

33. Interpretation of the results
 Consider any temperature decrease as zero rise. If no rabbit shows an
individual rise in temperature of 0.5 0 c / more above its respective control
temperature , the product meets the requirements for absence of pyrogens.
 If any rabbit shows an individual temperature rise of 0.5 0c or more
continue test using five other rabbits .
 If not more than three of eight rabbits show individual rise in temperature of
0.5 0c / more if sum of eight individual maximum temperature does not
exceed 3.3 0c the material under examination meets the requirement for
absence of pyrogens.

34. Limitations of rabbit pyrogen test
In vivo model
 A test method that uses a living animal as model will suffer from number
of problems offered by biological systems.
 No two rabbits will possess exactly the same body temperature or
respond identically to same pyrogenic sample.
 Rabbits are sensitive and vulnerable to their environment.
Rabbit sensitivity to pyrogens
 The pyrogenic response in rabbits is dose dependent.
 The greater the amount of pyrogen injected per kilogram body weight
the greater the temperature increase in rabbits.
 The rabbit test is less sensitive to endotoxin.
 It reports 50% pass/fail rate with 95% confidence at endotoxin level
above 0.098ng/m (9/10ml/kg) dose
 The greatest rise in temperature for any given dose of endotoxin
occurred in the afternoon , while the least raise occurred at midnight.

35. Interferences of the rabbit pyrogen tests
 Many products administered parenteral cannot be tested for pyrogens
with the rabbit test because of the interferences they create in the rabbit
response to pyrogens if they are present in the product
 Any products having a pyretic side effect such as the prostaglandins and
the cancer chemotherauptic agents will interfere with rabbit response.

36. LIMULUS AMOEBOCYTE LYSATE TEST(LAL)
In this test the presence of endotoxin is detected by formation of solid
gel.
Reaction mechanism
 Endotoxin or a suitably prepared lipid A derivative of endotoxin activates
a proenzyme of LAL having a molecular weight of 150,000.
 Activation also depends on the presence of divalent metal cations such
as calcium, manganese or magnesium. It has been shown that the
sensitivity of the LAL assay for endotoxin detection can be increased 10
to 30 times by using LAL reagent containing 50mM magnesium.
 The activated proenzyme related to the serine protease class containing
such enzymes as thrombin, trypsin and factor 10a subsequently with a
lower molecular weight protein fraction (MW=19000-25000) contained
also in the LAL substance.
 The lower molecular fraction called coagulogen is cleaved into soluble
and insoluble subunit .The insoluble subunit appears as a solid clot , or
a turbid solution depending on coagulogen.

37. Horseshoe crabs are placed in a
restraining rack and
passively bled for a few minutes. They are
promptly returned
to the sea unharmed. Amebocyte blood
cells are concentrated,
washed, and lysed to produce LAL
reagent.

38. Gel clot bacterial endotoxin test
 The gel clot end point is the most commonly used endotoxin test
 It is simple and requires minimal laboratory equipment
 Equal volumes of test solution and LAL reagent ( usually 0.1 ml of each) are
mixed in glass test tubes .
 After incubation at 37 degrees c for one hour tubes are observed for clot
formation after inverting them.
 Formation of solid gel clot that withstands inversion of the tube constitutes a
positive test.
 Each lot of gel clot reagent licensed by the FDA must be labeled with
sensitivity( lambda) to reference standard endotoxin(RSE).

39. Kinetic turbidimetric assay
 During LAL endotoxin reaction the solution mixture becomes increasingly
turbid
 The kinetic turbidimetric assay (KTA) requires the incubating micro plate or
tube reader driven by an endotoxin specific software.
 The reaction mixture in a KTA system are continuously monitored for
changes in optical density in each sample that are caused by scattering
and absorption of light.
 Generally the KTA measures the onset time needed to reach a
predetermined absorbance by each reaction mixture .
 The onset times for sample are compared with those of endotoxin studies
to yield quantitative values for each sample / control that contain endotoxin

40. Kinetic and endpoint chromogenic assay
 Chromogenic LAL test do not utilize the coagulogen proteins from LAL
reagent to produce an endpoint
 Although endotoxin activates the same enzymatic cascade from the
reagent as described above the clotting enzyme reacts with synthetic
substrate that has been added to the reaction mixture.
 The substrate consists of a colorless amino acid chain attached to a
chromophore.
 The activated clotting enzyme cleaves the bond that holds the
chromophore to the amino acid.
 The amount released is proportion to the concentration of endotoxin
 The chromophore that is released changes the color of the reaction mixture
thereby increasing the optical density
 After reaction is determined the absorbance is read over one log range.

42. Advantages compared to the rabbit test
Proponents of the LAL test claim that the test offers at least seven
advantages over the rabbit test for detecting pyrogens .
 Greater sensitivity
 Greater reliability
 Better specificity
 Less variation
 Wider application
 Use as a problem solving tool
 Less expense.
Researchers summarized the superiority of LAL test over the rabbit test
by following:
 After tens of thousands of tests an unexplained negative LAL test result –
rabbit positive test result was never recorded.
 Sometimes the rabbit test initially fails to detect pyrogens that were
sometimes confirmed by initial LAL tests.

43. Limitations of the LAL tests
 The greatest limitation of the LAL test is the problem of interference of
the lysate –endotoxin interaction that is caused by a variety of drugs and
other substances
 The reaction is mediated by clotting enzyme that is heat labile, pH
sensitive and chemically related to Trypsin .
 Inhibition caused by any material known to denature protein or to inhibit
enzyme action .
 Inhibition can be overcome by dilution or pH adjustment.
 Dilution reduces the concentration of endotoxin and places greater
demand on the sensitivity of the LAL regent to detect diluted amounts of
endotoxin.
LAL test applications
Used in atleast six different areas
pharmaceuticals, biologics, devices, disease states, food, validation of
dry heat cycles.

44. Assay
 Assay is performed according to method given In the monograph
of that parental preparation in the pharmacopeia
 Assay is done to check the quantity of medicament present in the
parenteral preparation.
 So we can know the exact amount of medicament present such that it
can perform its action.
 We should follow the official monograph IP/BP/USP for performing the
assay.

45. Sterility test
Sterility can be defined as the freedom from the presence of
viable microorganisms.
 It is done for detecting the presence of viable forms of bacteria, fungi and
yeast in parenteral products.
 The test for Sterility must be carried out under strict aseptic conditions in
order to avoid accidental contamination of the product during test.
 All glassware's required for the test must be Sterile.
 Sterility testing attempts to reveal the presence or absence of viable micro-organisms
in a sample number of containers taken from batch of product.
 Based on results obtained from testing the sample a decision is made as to
the sterility of the batch.

46. Major factors of importance in sterility testing :
 The environment in which the test is conducted
 The quality of the culture conditions provided
 The test method
 The sample size
 The sampling procedure
Environmental conditions :
 Environmental conditions avoid accidental contamination of the
product during the test.
 The test is carried out under aseptic conditions regular microbiological
monitoring should be carried out .
Culture conditions :
 Appropriate conditions for the growth of any surviving organism should
be provided by the culture media selection.

47. Factors affecting growth of bacteria :
 Nutrition
 Moisture
 Air
 Temperature
 pH
 Light
 Osmotic pressure
 Growth inhibitors
Culture media used for sterility testing:
 Fluid thioglycolate medium
 Soybean casein digest medium

48. Fluid thioglycolate medium(FTM):
 FTM provides both aerobic and anaerobic environments within the same
medium.FTM is an excellent medium for the detection of bacterial
contamination.
 Thioglycolate has the advantage of neutralizing the bacteriostatic
properties of mercurial preservatives.
COMPOSITION :
 L-cysteine , trypticase peptone, dextrose , yeast extract, sodium
chloride, sodium thioglycolate,resazurin,agar,purified water ,final pH 7.1
 specific role of some ingredients primarily intended for
the culture of anaerobic bacteria.
 incubation of the media: 14 days at 30 -35°C

49. Soybean casein digest medium:
Soya-bean casein digest medium primarily intended for the culture of both fungi
and aerobic bacteria specific role of some ingredients.
incubation of the media: 14 days at 20 -25°C
COMPOSITION
Trypticase soya broth, trypticase peptone, phytone peptone, sodium chloride ,
dipotassium phosphate, dextrose, purified water , final pH 7.3
Sterility test methods
 Direct inoculation method
 Membrane filtration method.
Membrane filtration methods
Selection of filters for membrane filtration :
 pore size of 0.45μ effectiveness established in the retention of micro-organisms
appropriate composition the size of filter discs is about 50 mm in
diameter

50. The procedure of membrane filtration
 sterilization of filtration system and membrane filtration of
examined solution under aseptic conditions.
 Filtration of the sample through a membrane filter having the
nominal size of 0.45μ and a diameter of 47mm.
 After filtration the membrane is removed aseptically from the
metallic holder and divided into two halves.
 The first half is transferred into 100 ml of culture media meant for
fungi and incubated at 20˚ to 25 ˚c for not less than seven days.
 The other half is transferred into 100ml of fluid thioglycolate
medium and incubated at 30 to 35 ˚c for not less than 7 days.

51. Advantages of membrane filtration over direct inoculation method
Greater sensitivity
 The entire contents can be tested providing an advantage in the sterility
testing of LVP and increasing the ability to detect contamination.
 The antimicrobial agent and antimicrobial solutes in the product sample can
be eliminated by rinsing prior transferring the filter into test tubes of media
thereby minimizing the incidence of false-negative test results.
 Organisms present in an oleaginous product can be separated from the
product during filtration and cultured in a more desirable aqueous medium.
Disadvantages
 This method cannot differentiate the extent of contamination between units
if present because all product contents are combined and filtered through a
single filter and cultured in single test tube.
 There exists a higher probability of inadvertent contamination in manual
operations .

52. Samples size to be taken
Number of articles in
batch (injectables)
Number of articles to be
tested
Not more than 100 articles 10%/ 4 articles whichever is
greater
More than 100 but not more
than 500
10 articles
For more than 500 2%/ 20 articles whichever is
less
For large volume
parenterals
2%/10 containers whichever
is less.

53. Direct inoculation method
 Required quantities of liquid is removed from the test containers with a
sterile pipette / sterile syringe.
 Aseptically transfer the specified volume of the material from each
container to vessel of culture medium
 Mix the liquid with medium but not aerate excessively
 Incubate the inoculated media for not less than 14 days , unless otherwise
specified in the monograph at 300c - 350c in the case of fluid thioglycolate
medium and 200c - 250 c for soybean casein digest medium.
 When materials examined renders the medium turbid so presence /
absence of microbial growth cannot be determined readily by visual
examination transfer suitable portions of medium to fresh vessels of the
same medium between 3 rd. and 7 th day after test is started.
 Continue incubation of the transfer vessel for not less than 7 additional
days after transfer and total of NLT 14 days.

54. Interpretation of results
At the end of the incubation period the following observations are possible:
 No evidence of growth; hence the preparation being examined passes the test
for sterility.
 If there is evidence of growth, retesting is performed using the same number of
samples, volumes to be tested and the media as in the original test. If no
evidence of microbial growth is then found, the preparation being examined
passes the test for sterility.
 If There is again evidence of the microbial growth then isolate and identify the
organisms. If they are not readily distinguishable from those growing in the
containers of the first test then the preparation being examined fails the test for
sterility.
 If they are distinguishable from the organisms of the first test then again do the
test using twice the number of samples. The preparation being examined
passes the test for sterility in case there is no evidence of microbial growth. In
case there is evidence of growth of any micro organisms in second re –test,
the preparation being examined fails the tests for sterility.

55. Test for packaging containers
Powdered glass Test:
 Use crushed glass containers in 250-ml conical flask, add 50 ml high purity
water, cap the flask with borosilicate glass beaker
 Place the containers in the autoclave and close it securely hold temperature at
1210c±20c for 30 min., counting from the time this temperature is reached.
 cool the flask, decant the water from the flask into a clean vessel, and wash the
residual powdered glass with high purity water, add 5 drops methyl red solution,
titrate immediately with 0.02 N sulfuric acid .
 Record the volume of 0.02N Sulfuric acid used to neutralize the extract from 10
g of the prepared specimen of glass.
Type Type of
test
Size
(ml)
ml of
0.02N
H2SO4
ˡ Powder
glass
All 1.0
ˡˡ Water
attack
100/less
Over
100
0.7
0.2
ˡˡˡ Powder
glass
All 8.5
Non
parenter
al
Powder
glass
All 15.0
Water attack at 121°C
 Rinse 3 or more containers with high purity
water.
Fill each container to 90% of its capacity with
high purity water.
 Cap all the flasks with borosilicate glass
beaker, place in the autoclave at 121 C for 60
min

56. Test for plastics
Leakage test
10 containers are filled with the parenteral fluid and inverted
for 24 hrs. and checked for any leakage.
Transparency
Dilute the preparations and compare the cloudiness with the control that is
water.
Water vapor permeability
Containers stored at 20-25o c at 60±5% Rh for 14 days and check for water
vapor permeability.
Rubber closure tests
Sterilization
Fragmentation
Self sealability
Clarity and color

57. Labels and labeling
 The label states the name of the preparation (in case of a
liquid preparation)
 The percentage content of drug in a specified volume (in
case of dry preparation)
 The route of administration
 Storage condition
 Expiration date
 Name of the manufacturer
 The lot number
 Containers for injection that are intended for use as dialysis, or
irrigation solution are labeled to indicate that the contents are not
intended for use by iv infusion
 Injection intended for veterinary use are labeled to that effect
 The containers are so labeled that a sufficient area of the container
remains uncovered for its full length to permit inspection of the
contents

58. UNIFORMITY OF CONTENTS:
 Unless otherwise stated in the individual monograph, suspensions for
injection that are presented in single dose containers and that contain
less than 10mg or less than 10 % of active ingredient comply with the
following test.
 For suspensions for injection containing more than one active ingredient
carry out the test for each active ingredient that corresponds to above
conditions.
 The test for uniformity of contents should be carried out only after the
content of active ingredient in a pooled sample of the preparation has
been shown to be within accepted limits of the stated content.
 Determine the content of active ingredient of each of 10 containers taken
at random, using the suitable analytical method of equivalent accuracy
and precision.

59.  The preparation under examination complies with the test if the individual
values thus obtained are all between 85 and 115 % of the average value.
 The preparation under examination fails to comply with the test if more
than one individual value is outside the limits 85 to 115% of the average
value or if any one individual value is outside the limits 75 to 125% of the
average value.
 If one individual value is outside the limits 85 to 115% but with in the limits
75 to 125% of average value, repeat the determination using another 20
containers taken at random.
 The preparation under examination complies with the test if in the total
sample of 30 containers not more than one individual value is outside the
limits 85 to 115% and none is out side the limits 75 to 125% of the average
value.

60. UNIFORMITY OF WEIGHT:
 For powders for injection that are required to comply with the test for uniformity of
content of all active ingredients ,the test for uniformity of weight is not required.
 Remove any adherent labels from a container and immediately weigh the
container and its contents.
 Empty the container as completely as possible by gentle tapping, rinse if
necessary with water and then with Ethanol (95%) and dry at 1000 c to 1050 c for
1hr.
 If the nature of the container precludes such treatment, dry at a lower
temperature to constant weight.Allow to cool in a desiccator and weigh.
 The difference between the weights represents the weight of the contents.
 Repeat the procedure with a further 19 containers and determine the average
weight.
Not more than two of the individual weights deviate from the average weight by
more than 10% and none deviate more than 20%.

61. Documentation
Document is a paper that provides information especially
of an official or legal nature, written report or record.
Documentation is a method of preparing a written material, which
describes the process in terms of specifications, instructions etc.
Documentation and records are essential for obtaining accreditation,
certification of ISOs and approvals by Federal Bodies.

62. Importance Of Documentation of Records
 Provide working details necessary for manufacturing,
packaging and QC.
 Reduce the risk of mistakes inherent in verbal communication.
 Help in tracing the deviation from the expected yields.
 Help in decreasing the batch to batch variations so that the quality
of product kept within the limit of acceptability.
 Considered as history of batch operations.
 Self inspection of procedures in order to achieve better control of
operations and improvement of product design

63. Important areas of documentation
 Particulars with respect to their storage, stability & handling.
 Instructions of all manufacturing & packaging procedures, preferably batch wise
are documented so that no further calculations are required at the work of floor
level.
 Instructions for non product related operations such as cleaning & disinfections,
maintenance of equipment, monitoring of working conditions use of specific
conditions.
 Records such as batch manufacturing record, batch packaging record, test record for
no product related operations as indicate.
 Procedures for testing for e.g. physical, chemical, microbiological. Etc. to be followed.
 Specifications of starting material packaging materials and product for the
compliance by the quality control department.

64. Document, Document, Document!!!
In FDA-speak:
“If it is not
documented . . .
it did not
happen!”
or, it’s a
rumor!”

65. OBSERVATION
PAREMETERS
OBSERVATIONS / ACCEPTANCE CRITERIA
Date -
Time Observation should be recorded at an interval of one hour
a)Manufacturing area
General cleanliness Floor, walls, ceiling ,fans, window panels and ledges should be
visibly free from dirt, dust foreign matter.
RH/temperature Note the RH and temperature on the hygrometers
Insect trap/ air curtain-
ON
Should be in operation.
Status label for
All tanks
Jacketed vessels
Other accessories
All manufacturing and storage tanks , jacketed vessels, filter
press, pipes, colloidal mills & other accessories should be
labeled with CLEANED or TO BE CLEANED or product label
with details of product name, mfg. date stage and date of
processing.

66. Raw materials other than the
current batch removed
Raw materials only for batch under process should
be required for present and others should be
removed from process area.
All tanks properly covered All manufacturing & storage tanks should be covered
with lids
Status label for
Balance
Sifter
Multi-mill
Blender
Tray drier
Other accessories
All in-process materials
Packaging
Labeling
Segregation
quarantine
RM quality during sifting
Sugar quality after milling
Blend quality

67. Packaging area
General cleanliness Floors, walls, ceiling, fans and ledges should be visibly free
from dust and foreign matter.
Insect trap/air curtains-
ON
Should be in operation
Status label present for
Packaging/filling area
Filling machine
ROPP cap sealing
machine
Packaging / filling area, filling machine ,sealing machine
should be labelled with CLEANED or TO BE CLEANED or
product label with details of product name , batch name,
mfg. date stage & date of processing.
Packaging materials
other than that required
for current batch removed
Packaging materials only of the batch under packaging
should be present and others should be removed
Bottle washing
Water sprinkler
Check all the water jets of the bottle washing machine are in
working condition
Washing bottles –check The glass bottles should be free from physical defects. Pour
filtered water into bottles close and check the bottles again
,should be free from particles, fibres.

68. Filling tanks
Labelled
Cover present/ absent
Solution level NLT 1/4 of
tank height
Product label with product details must be present
Tanks should be covered during filling process
Solution level should be NLT ¼ of tank height.
ROPP cap
No visual defects
cleanliness
Sealing/threading
Ease of cap opening /re-sealing
Should be free from damages and monogram should be
uniform and should be in Centre.
Caps should be free from dust and metallic particles
Sealing should be complete threading should be without
cuts.
Should open properly with good bridge cutting and
should reseal properly without over turning.
Leak test
Before seal opening
After re-sealing
Invert the filled ,sealed bottles &keep for 30min .it should
not leak.
Open the cap and reseal ,invert the bottle again and
check for leakage.
Check on filled bottles
Sealing
Volume
Foreign matters and defects
Sealing should be proper without cuts
Check as per BPR
Should be free from foreign matter and glass.

69. Coding details
B.No/Mfd./Exp./price
Clarity
Positioning
Check all coding details on labels and cartons and compare
with BPR and signed specimens
Clarity of printing should be free from ink smudges.
Position of coding details should be proper against each
detail.
Labelling
Soiling/smudging
Print clarity
Positioning
Gumming
Labels should be free from soiling and printed matter should be
free from smudging
Printed matter & colors should be uniform shades & clear
Pasting of labels should be proper without cross labelling or
wrinkles.
Should be proper without excess gum
Carton
Printing clarity
Coding details/clarity
Carton erection & closing
Should be of uniform shades and clear
Coding details should be compared with BPR and signed
specimens and be clear & properly positioned
Should be neat and definite with proper bottom. Sides locking.
Closing should seal properly & shouldn't open out
Leaflet Presence of proper literature should be properly checked printing
matter and folding should be proper.

70. Measure cup/ dropper
Cleanliness
Free from visual defects
Fixation of cup/dropper
assembly
Should be clean and visually free from any foreign matter
Should be free from dents, scratches, breakage.
Cups should fix to the bottle neck with slight push and
should not fall out when lifted.
Corrugated box –external
Address/position/clarity
Handling cautions/ position
Pack slip
Stapling
Stacking
Should be printed on left bottom side printing should be without
smudges
Should be printed on another length wise portion opp to printing of
address in middle of panel.
Should be pasted with details properly stamped , for trade name
products, with monogram& generics monogram
Good quality rust proof should be used & should be used at 45
deg angle NT 60 mm b/w two stapling.
Should be properly stacked & lower box should withstand the
weight.
Corrugated box internal
Liners & partitions
contents
Liners should be placed properly & formation of partition should
be uniform.
Should comply as per the instructions & quantities to be pkd

71. Master formula records
Name of the product________________________________________
Name and Weight of API ____________________________________
Name and Weight of Ingredient _______________________________
Description of equipment ____________________________________
Statement of theoretical yield_________________________________
Process and packaging procedure_____________________________
A description of container____________________________________
closure and packaging material _______________________________
In process control during processing ___________________________
In process control during packaging____________________________
Precaution to be taken______________________________________

72. Environmental control
Product_______________________________ lot no._______________
Room____________________ date exposed_____________________
Media__________________________
Date Time Incubation
temperature
Humidity in case of
hygroscopic substances’
Plate no duration Location No of colonies

73. Preparation of equipment's and containers
Description of containers ___________________________________
Q/C report of container ____________________________________
Date ________________________ Equipment used______________
Cleaning agent used ________________________________________
Cycle of washing: __________________________________________
Sign. Of officer____________________________________________
Articles Date Time when oven
started
Desired temp
attained
Temperature Time when oven
switched off
If sterilized by dry heat or autoclave

74. Filtration and filling
Equipment's used for filtration ___________________________________
Date__________________________ Time_________________________
Result of test or analysis of solution_______________________________
Equipment used for filling_______________________________________
Date________________________________________________________
Sign. Of officer____________________________________________
Time Filling started Filling completed

75. Ampoule filling on industrial scale
followed by terminal autoclaving
Ampoule filling on small scale
Steps of filling and sealing
Powder filling machine in vials and
ampoules

76. IPQC RECORDS
Visual inspection:
Description ___________________
Total no of filled, sealed & sterilized containers rejected ___________
Nature of defects ___________________________________
Name of worker who examined
(i). ________________________________________________
(ii). _______________________________________________
(ii). _______________________________________________

77. Batch packaging and labeling records
Product name_______________________
Batch no_______________________
Strength___________________________
batch size ______________________
Category___________________________
mfg. date _______________________
MFG no_________________________
exp date _______________________
Description of packaging ______________
Pre-coding of labels & printed packaging materials
Examined verified by_____
No. of pre-coded __________________________
Printed packaging material received _____________________
Result of bulk finished products ______________________
Sign. Of officer ___________________________________________

78. Problems encountered and their remedies
Problem encountered Remedy
Leakage of ampoules Discard the ampoule
Use new ampoule with
proper sealing
Perforation in filter leading
to defective filtration
Changing the filter
Foreign particles/dust Membrane filtration
Fibres Optical and visual
inspection
pH Use of buffers
Leaching Internal coating of glass
containers.

79. References
 Encyclopedia of pharmaceutical technology third edition edited by
James Swabrick volume 5.
 Indian pharmacopeia (1996) volume 2
 United states pharmacopeia (2000) volume 2
 Pharmaceutical dosage forms : parenteral medications volume 3
by Kenneth E Avis; Herbert A Lieberman; Leon Lachman.
 The Theory and Practice of Industrial Pharmacy by
Leon Lachman ; Herbert A. Lieberman ; Joseph L. Kanig.
 Parenteral Quality Control: Sterility, Pyrogen, Particulate and Package Integrity
Testing
By (author) Michael J. Aker; Revised by Dana Morton Guazzo.
By Daniel S. Larrimore.

80.  IPQC PowerPoint presentation from author stream by Govind Bhandari
from Mahakal institute of pharmaceutical studies.
 Sterile Dosage Forms I. Parenteral Products by Professor Dr. Nagia
Nagib Afifi by German university in Cairo ( GUC).
 Pharmaceutical practical guide.
 Some PowerPoint presentations from slideshare.
 Product management and Documentation by professor of East west
college of pharmacy Bangalore.