This document is an industrial training report submitted by Omagor Nicholas, a second year chemical engineering student at Kyambogo University. The report details his 8-week industrial training at Cipla Quality Chemical Industries Limited (CiplaQCIL), a pharmaceutical manufacturing plant in Kampala. The report includes sections on quality assurance, stores management, quality control, production processes, and engineering systems at the plant. It also discusses the objectives and methodology of the training, as well as lessons learned and recommendations.
A field attachment report to help all those preparing to write a report after completion of their field attachments. I wrote this Myself in 2011, During my first year of study at Zanzibar University, Tanzania.
Industrial Attachment Report at ZIMVET Laboratory (Irvines Zimbabwe), August ...Joseph Kunashe Ndondo
An Industrial Attachment Report compiled and submitted in partial fulfilment of the requirements for the degree of Bachelor of Science Honours degree in Applied Biology and Biochemistry
A field attachment report to help all those preparing to write a report after completion of their field attachments. I wrote this Myself in 2011, During my first year of study at Zanzibar University, Tanzania.
Industrial Attachment Report at ZIMVET Laboratory (Irvines Zimbabwe), August ...Joseph Kunashe Ndondo
An Industrial Attachment Report compiled and submitted in partial fulfilment of the requirements for the degree of Bachelor of Science Honours degree in Applied Biology and Biochemistry
Final Internship Report by kiyimba Bill (International University Of East Afr...Bill Kiyimba
An Internship / Field Attachment report sample format for fulfillment of the requirements of the degree in Software engineering, Computer science and Information Technology.
Nhận viết luận văn Đại học , thạc sĩ - Zalo: 0917.193.864
Tham khảo bảng giá dịch vụ viết bài tại: vietbaocaothuctap.net
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This report is based on the internship experience I had during my time of internship. The relevant details of the internship program are available in the cover page. This report contains three main chapters namely, Introduction to the Training Establishment, Training Experience and Conclusion. In the following paragraphs, what each chapter contains is explained briefly.
The first chapter is titled, “Introduction to training establishment” and it contains information about the organization that I had my training at.
The second chapter includes information related to the training experience I had, during my time of stay at the training establishment.
The final chapter is the conclusion of the report, where it contains a summary of the training experience mentioned in chapter 2 and how all these training experiences affected my life and career and it distinguishes the university life from the training life, by clearly mentioning what I gained as an intern in that company.
This is a dissertation on The Use of Cause Marketing and the Mediating Effect of Publicity on Customer Retention. Findings from the research conducted would be very useful to academics, marketing and marketing communication practitioners.
Final Internship Report by kiyimba Bill (International University Of East Afr...Bill Kiyimba
An Internship / Field Attachment report sample format for fulfillment of the requirements of the degree in Software engineering, Computer science and Information Technology.
Nhận viết luận văn Đại học , thạc sĩ - Zalo: 0917.193.864
Tham khảo bảng giá dịch vụ viết bài tại: vietbaocaothuctap.net
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This report is based on the internship experience I had during my time of internship. The relevant details of the internship program are available in the cover page. This report contains three main chapters namely, Introduction to the Training Establishment, Training Experience and Conclusion. In the following paragraphs, what each chapter contains is explained briefly.
The first chapter is titled, “Introduction to training establishment” and it contains information about the organization that I had my training at.
The second chapter includes information related to the training experience I had, during my time of stay at the training establishment.
The final chapter is the conclusion of the report, where it contains a summary of the training experience mentioned in chapter 2 and how all these training experiences affected my life and career and it distinguishes the university life from the training life, by clearly mentioning what I gained as an intern in that company.
This is a dissertation on The Use of Cause Marketing and the Mediating Effect of Publicity on Customer Retention. Findings from the research conducted would be very useful to academics, marketing and marketing communication practitioners.
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Credits of the paper are to the Philippine Department of Environment and Natural Resources.
This paper was included in the event kit of Green Bloggers Forum, held 7 June 2016 at the Cocoon Boutique Hotel, QC, Philippines. The DENR authorized all bloggers and participants to promote the information and materials during the event.
In 2007 the iPhone was the next big thing. It was revolutionary because it was totally unexpected and really was something revolutionary in the world of clamshell mobile phones. But every year since, Apple has just re-released the same phone, only with slightly better specifications. This is an evolution, not the revolution as touted by that fruit company. Also, we reveal the specs of the upcoming iPhone 6. And the specs for the next 6-7 years of iPhones!
Automotive air filter ppt available here all the data u needed for giving ppt in college online and it will help u in seminar also so just get it, it will help alot. "GET THE SHORT VIDEO OF AIR FILTER MANUFACTURING FROM (HOW ITS MADE)" AND IMPLEMENT THAT IN SLIDE after raw material. it will help you in presentation.
26 Disruptive & Technology Trends 2016 - 2018Brian Solis
Introducing the “26 Disruptive Technology Trends for 2016 – 2018.” In this report, we’ll explore some of the disruptive trends that are affecting pretty much everything over the next few years at least those that I’m following. It’s not just tech, though. The report is organized by socioeconomic and technological impact.
Obviously, this is not an exhaustive list of every technology and societal trend bringing about disruption on planet Earth. What follows thought definitely affects the evolution of digital Darwinism, the evolution of society and technology and its impact on behavior, expectations and customs.
Industrial Training Report- AKTU Industrial Training ReportAvinash Rai
Title: Maximizing Industrial Training Benefits: A Comprehensive Guide
Introduction:-
Welcome to our comprehensive guide on industrial training and its myriad benefits.
Learn how to optimize your industrial training experience for maximum growth and skill development.
Understanding Industrial Training:-
Definition: Industrial training refers to a structured program that integrates academic knowledge with practical application in a professional setting.
Importance: It bridges the gap between theoretical learning and real-world industry practices.
Key Components of Industrial Training:-
Practical Experience: Hands-on learning in a real workplace environment.
Mentorship: Guidance from experienced professionals in the field.
Skill Development: Enhancement of technical, interpersonal, and problem-solving skills.
Benefits of Industrial Training
Enhanced Skill Set: Gain practical skills relevant to your field of study or career path.
Industry Exposure: Acquire firsthand knowledge of industry practices and trends.
Networking Opportunities: Connect with professionals and build valuable contacts for future endeavors.
Career Advancement: Increase employability and stand out in the job market with relevant experience.
Personal Growth: Develop confidence, adaptability, and problem-solving abilities.
Resume Enhancement: Strengthen your resume with valuable practical experience.
Potential Job Offers: Impress employers and increase your chances of securing job offers post-training.
Insight into Work Culture: Understand workplace dynamics and organizational structures.
Professional Guidance: Receive mentorship and guidance from seasoned professionals.
Test-Drive Careers: Explore different career paths and industries to make informed decisions about your future.
Case Studies
Highlight successful industrial training experiences and their impact on participants' careers.
Showcase testimonials from trainees and employers on the benefits of industrial training.
Slide 8: Conclusion
Industrial training offers invaluable opportunities for skill development, career advancement, and personal growth.
By implementing the strategies outlined in this guide, you can maximize the benefits of your industrial training experience.
Embrace every opportunity to learn, grow, and excel in your chosen field.
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Industrial Training
AKTU report
AKTU Industrial Training Report
Internship report on concepts of modern merchandising tools and techniques in...Muhammad Rahat
Ready-made garments are fast growing export sector in Bangladesh. The overall impact of ready-made garments export is certainly one of the most substantial social and economic developments in present Bangladesh. In order to pretend rapid growth of the country, particularly through industrialization, the government has implemented an open entry policy to attract overseas investment in Bangladesh. As results there are about 2500 export focused on readymade garments exists in Bangladesh.
For some recent consecutive accident in our garments sector is negatively impact on our apparel sector. For that reason, compliance issued came in front. In recent days the word compliance in ready – made garments sector have the experience that the customers are giving so many conditions to comply by the manufacturer, In the past whatever buyers came to the factory to place order they used to see the quality of the garments that are being procedure in the factory. But now the ultimate customers in the western world have become more cautious and want to know the origin of the apparels. And in the garments sector one of the most important task is merchandising.
Merchandising is one of the important works in garments sector. In every garment merchandiser job is every essential. In this job the employer need to have hard working mind, substantial power, prompt intelligence, great observation, tolerance etc. Without merchandiser no garments can run efficiently.
For every garment buyer is the heart of their business. For this reason, buyer satisfaction is most vital for a garment. Buyer means the persons or organizations who buy the products from any organization. In garments sector of Bangladesh buyer means especially foreign buyer who buy products from our garments. And this satisfaction ensuring duty performs by the merchandiser. The first task of the merchandiser is to bring foreign buyer to buy the product through effective communication. At the time of giving order if buyer satisfied with the help of merchandiser then they will come again. Buyers another condition is delivery the products in right time. Merchandiser take care this challenge seriously. Because if buyers do not get products in right time then they will not give the order again to that garments. So merchandisers are handling and caring all kinds of work from receiving order to delivering products to buyers and always wants to please them because garments or garments sector’s development depends on buyer’s satisfaction.
I have selected ready-made garments industry to do my internship because I wanted to obtain knowledge about the merchandising activities. Recently I work in Woolen & Wool Ltd. “Woolen
1. KYAMBOGO UNIVERSITY
TITLE: INDUSTRIAL TRIANING REPORT
NAME OF STUDENT: OMAGOR NICHOLAS
REG. NO: 13/U/7251/CHE/PE
YEAR OF STUDY: YEAR II
ACADEMIC YEAR: 2014/2015
PROGRAM OF STUDY: BACHELOR OF SCIENCE IN CHEMICAL ENGINEERING
NAME OF INDUSTRY: CIPLA QUALITY CHEMICALS INDUSTRIES LTD
2. i
DECLARATION
I OMAGOR NICHOLAS a student of KYAMBOGO UNIVERSITY declare that I have
written this report myself as an academic requirement. All the material contained in this report is
an original record of the work and activities I was involved in during my industrial training at
CIPLA QUALITY CHEMICAL INDUSTRIES LIMITED (CiplaQCIL).
…………………………………
3. ii
APPROVALS
This is to certify that OMAGOR NICHOLAS had his industrial training for eight weeks here at
CiplaQCIL and that this report is a true record of the work he did under our supervision.
Signature……………………………….. Date……………………………………
Mr. JOHN KAMILI
INDUSTRIAL SUPERVISOR
Signature………………………………… Date…………………………………….
Mr. MANANO JOHN
ACADEMIC SUPERVISOR
4. iii
DEDICATION
This document is dedicated to my dear parents Mr. and Mrs. Enginyu, lecturers of Kyambogo
University, the staff of CiplaQCIL and to my fellow class mates.
It is most especially dedicated to those who directly or indirectly assisted during my training at
CiplaQCIL.
5. iv
ACKNOWLEDGEMENTS
It is always a pleasure to remind the fine people at CIPLAQCIL for the sincere guidance I
received to uphold my practical as well as theoretical skills in engineering.
Firstly, I would like to thank CIPLAQCIL for convincing me on the saying that “Whatever is
imagined, can be achieved”, treating me as an employee of their own and guiding me to the real
flavour of engineering discipline.
Secondly, I would like to thank the staff at CIPLAQCIL for the positive attitude they should for
my work, always allowing me to question them and giving prompt replies for my uncertainties in
all the fields including educational, social and managerial to labor work.
Thirdly I would like to thank Ms. Achen Irene of Department of quality assurance and Mr.
Kamili John regulatory affairs executive for extending their friendship towards me and making a
pleasure-training environment at the factory. A paper is not enough for me to express the support
and guidance I received from them almost for all the work I did there.
Mr. Manano John our academic supervisor for checking on us at the factory and giving us
support on how to go about with the training. Opening our minds on some areas we didn’t raise
queries in the training.
I thank all the trainees who underwent training with me the mutual support I received from them.
Department of chemistry Kyambogo is much thanked for allowing me to have my training in
CIPLAQCIL.
I also would like to thank my family for the support they gave to me during this whole internship
period making sure I turn up on time and all that I can’t mention.
Finally I apologize all other unnamed who helped me in various ways to have a good training
Knowledge is power and unity is strength.
6. v
ABBREVIATIONS;
ACF-ACTIVATED CARBON FILTER
AHU-AIR HANDLING UNIT
API- ACTIVE PHARMACEUTICAL INGREDIENT
ARV-ANTI RETROVIRAL
BMR-BATCH MANUFACTURING RECORD
BPR-BATCH PACKAGING RECORD
CAPA- CORRECTIVE AND PREVENTIVE ACTION
cGLP- current GOOD LABORATORY PRACTICES
cGMP – current GOOD MANUFACTURING PRACTICES
CiplaQCIL –CIPLA QUALITY CHEMICALS INDUSTRIES LIMITED
DT-DISINTERGRATION TIME
EDTA- ETHYLENE DIAMINO TETRA ACETIC ACID
EFV- EFAVIRENZ
ETP- EFFLUENT TREATMENT PLANT
FAT-FACTORY ACCEPTANCE TEST
FBE-FLUIDIZED BED EQUIPMENT
FIFO/FEFO-FIRST IN FIRST OUT /FIRST EXPIRY FIRST OUT
GC-GAS CHROMATOGRAPHY
GMP-GOOD MANUFACTURING PRACTICES
GRN- GOODS RECEIVED NOTE
7. vi
HDPE- HIGH DENSITY POLYETHENE
HPLC-HIGH PERFOMANCE LIQUID CHROMATOGRAPHY
HVAC-HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
IPA-ISOPROPYL ALCOHOL
IPQC-IN PROCESS QUALITY CHECKS
IRS – INFRA RED SPECTROSCOPY
LAF-LAMINAR AIR FLOW
MGF-MULTIGRADE FILTER
MIPC-MACHINERY IN PROCESS CONTAINER
NDA-NATIONAL DRUG AUTHORITY
NMT-NOT MORE THAN
NWSC-NATIONAL WATER AND SEWAGE COOPERATION
PVC-POLYVINYL CHLORIDE
QA-QUALITY ASSURANCE
QCIL-QUALITY CHEMICALSINDUSTRIES LIMITED
QC-QUALITY CONTROL
R&D- RESEARCH AND DEVELOPMENT
RH-RELATIVE HUMIDITY
RMG-RAPID MIXER AND GRANULATOR
RO-REVERSE OSMOSIS
SAT-SITE ACCEPTANCE TEST
8. vii
SCA-SUBAROUD CHLORAMPHENICOL AGAR
SCDA-SOYA BEAN CASEIN DIGEST AGAR
SDI-SLIT DENSITY INDEX
SMB-SODIUM METABISULPHATE
SMG-SAIZONER MIXER, GRANULATOR
SOPs- STANDARD OPERATING PROCEDURES
SPV-SOLUTION PREPARATION VESSEL
SS-STAINLESS STEEL
TRIPS -TRADE RELATED INTELLECTUAL PROPERTY RIGHTS.
UV-ULTRA VIOLET
VMP-VALIDATION MASTER PLAN
9. viii
ABSTRACT
Industry training started on the 1st June for 8 weeks. Industrial training for undergraduates in
Uganda universities is widely practiced. It provide hands-on experience and up-to-date
information to the graduates who are about to enter the competitive job market.
The report identifies specific approaches used for collecting the data on daily basis. It points out
areas of experience gained from observations, interactions, hands on practice and analysis of
data.
The document highlights main findings of the training in the domain of management, unit
operations, marketing, packing and storage that at all levels insured quality.
However the report mentions some key challenges that could be useful in future review of field
tools for chemical engineering students and recommends actions for future improvements.
In conclusion, the report points out good practices in the industry, a linkage between theoretical
exposure from the university and practical experience at the industry.
10. 1 Contents
DECLARATION................................................................................................................................ i
APPROVALS................................................................................................................................... ii
DEDICATION................................................................................................................................. iii
ACKNOWLEDGEMENTS................................................................................................................iv
ABBREVIATIONS............................................................................................................................v
ABSTRACT...................................................................................................................................viii
1 INTRODUCTION AND BACKGROUND...................................................................................1
1.1 INTRODUCTION...............................................................................................................1
1.2 BACKGROUND.................................................................................................................1
1.3 OBJECTIVES OF TRAINING.............................................................................................2
1.4 TRAINING METHODOLOGY............................................................................................2
2 QUALITY ASSURANCE...........................................................................................................3
2.1 ROLES OF QA ...................................................................................................................3
2.2 GOOD MANUFACTURING PRACTICES. (GMP)..............................................................4
2.3 PHARMACEUTICAL QUALITY SYSTEM........................................................................4
2.4 cGMP .................................................................................................................................5
2.5 SELF INSPECTION:...........................................................................................................7
2.6 COMPLAINTS AND RECALLS:........................................................................................8
2.7 VALIDATION....................................................................................................................8
2.8 QUALIFICATION;...........................................................................................................10
2.9 DOCUMENTATION;........................................................................................................12
3 STORES...................................................................................................................................13
3.1 RECEIVING BAY AREA..................................................................................................14
3.2 RAW MATERIAL QUARANTINE AREA.........................................................................14
3.3 SAMPLING AREA. ..........................................................................................................14
3.4 APPROVED RAW MATERIAL AREA. ............................................................................15
3.5 DISPENCING...................................................................................................................15
3.6 PACKAGING MATERIAL STORES.................................................................................15
12. 1
1 INTRODUCTION AND BACKGROUND
1.1 INTRODUCTION
Kyambogo University like any other university would like to maintain standards and integrity in
the employment market so as their students are attractive to the future employeers.it is on this
perspective the university emphasizes on both theoretical and practical training for their students
.As for the program of bachelor of science in chemical engineering, usually at the end of
semester two of your second or third year, one is granted the opportunity to take part in industrial
training as part of the academic requirement. This is done under the supervision of the university
and the factory technical personnel.
1.2 BACKGROUND
According to the national development plan (2014/2015) the policy of the country prioritises on
promotion of science and technology hence the need to support the training of science students
especially engineers in order to reduce the human resource gap in economic development. In
response to this government thru ministry of Education has made provisions for science students
to go to university through student’s loan scheme and government sponsorship. The country
relies more on imported human resource for its highly trained labour market .Kyambogo
university is one of the beneficiaries among the public university. It is traditionally renowned for
its competent engineers because of its emphasis on practical skills, partnership with local
industries and institutions. In chemical engineering, there are number of chemical based
industries which are in partnership with the university. They have state of the art modern
facilities suitable for industrial training. Most of the industries are in support of the industrial
training of students to increase potential source of labour. Potential industries in need of the
chemical engineers include pharmaceuticals, food processing plants, oil refineries, breweries and
mineral processing plants just to mention but a few. The university has therefore encouraged
students to apply to any of the industries for placement, because they provide more knowledge,
skills and practices for effective modelling of students for future employers. It is in view of this,
I was fortunately selected by Cipla Quality Chemical Industries Limited (CiplaQCIL) against
competing demands from other universities.
13. BRIEF INFORMATION ABOUT THE COMPANY:
Cipla Quality Chemical Industries Limited (CiplaQCIL) is a state of the art pharmaceutical
manufacturing plant located in Kampala, specializing in manufacturing Anti-retroviral drugs
(ARVs) and Artemisinin-based Combination Therapies (ACTs) to combat HIV/AIDS and
Malaria respectively.
The company was founded in June 2005 as a joint venture between Quality Chemicals Limited
(QCL), a Ugandan company dealing in the importation and distribution of pharmaceutical drugs,
and Cipla Ltd, a leading Indian pharmaceutical company. The joint venture then attracted
Capitalworks Investments of South Africa at 14.4% and TLG Capital Investment of United
Kingdom at 12.5% leaving Cipla and QCIL at 36.55% each with a vision to become a center of
pharmaceutical manufacturing excellence in the region.
QCIL sold more shares to Cipla Ltd. in 2013 to facilitate more pharmaceutical production and
technology transfer. Cipla now owns 51.05% of the shareholding with QCIL holding onto
22.05%. CiplaQCIL is designed to meet the world’s most stringent pharmaceutical regulatory
standards and is pre-qualified by the World Health Organization (WHO) as an additional
contract manufacturing site for Cipla Ltd antiretroviral and anti-malaria
1.3 OBJECTIVES OF TRAINING
The objectives are based on identified training needs from students and employers. They
specifically include:
To gain practical work experience and to be able to see theory in practice.
To learn accepted safety practices in the industry.
To develop personality and communication skills for future roles as leaders in the
scientific and technological world.
To improve the student’s manual skills associated with scientific and technological
operations in the manufacturing industry.
1.4 TRAINING METHODOLOGY
The industrial training considers a range of methods for collecting data and analyzing it which
informed the field report writing. Specific methods included
14. Data collection forms from the university and industry.
The industry provided a checklist on what was to be learnt in each department
Orientation was done in two days from both the outside and inside of the facility. It was
done on rotational basis from one department to another.to allow everybody to know
what happens in every unit.
Reading documentation like SOPs which were available in all the rooms in the facility for
safety and quality assurance purposes.
In order to gain deeper understanding of the industrial training, discussions with
supervisors were done. Academic and industrial supervisors were also tracking the
performance to ascertain we are in the right direction.
Some activities such as sifting, packing, in process checks, validation were done
practically so as to gain confidence.
2 QUALITY ASSURANCE
With regard to pharmaceuticals, quality assurance can be divided into major areas: development,
quality control, production, distribution, and inspections. With regard to pharmaceuticals, quality
assurance can be divided into major areas: development, quality control, production, distribution,
and inspections.
2.1 ROLES OF QA
Responsible for all quality management systems of the facility
Approving or rejecting all components, drug product containers, closures, in-process
materials, packaging material, labelling and drug products.
Review production records.
Ensure that if errors have occurred, that they have been fully investigated.
Approving or rejecting drug products manufactured, processed, packed or held under
contract by another company.
Approving or rejecting procedures or specifications
QA ensures all activities involved in all the above departments are done the right way as
stipulated in the SOPS and cGMP is followed.
15. The QA department is made up of the following areas;
QA office
Document room ,were records are kept
Training Centre were training takes place from.
It operates on the following principles;
Quality safety and effectiveness must be designed and built into a product
Quality isn’t tested it’s made.
Responsibility for quality is a collective one is all individuals involved.
Quality aims at continuous improvement of systems
Each step of manufacturing process must be controlled to maximize the probability that
the finished product meets all quality and design specifications hence process validation.
2.2 GOOD MANUFACTURING PRACTICES. (GMP)
GMP protects patients. GMP ensures that they receive medicinal products of uncompromised
high quality. Compliance with these quality standards is imperative during the manufacture,
processing, packaging and storage of medicinal products. Manufacturing authorization will be
denied to any company that fails to comply with GMP regulations. This is governed all over the
world by acts of law, regulations and guidelines issued by government bodies, ministries and
international organizations. Their goal is to put safe and effective medicinal products on the
market with no harm to the patients.
2.3 PHARMACEUTICAL QUALITY SYSTEM
The manufacturer must assume responsibility for the quality of the pharmaceutical products to
ensure that they are fit for their intended use, comply with the requirements of the marketing
authorization and do not place patients at risk due to inadequate safety, quality or efficacy. To
achieve this quality objective reliably there must be a comprehensively designed and correctly
implemented pharmaceutical quality system (PQS) incorporating GMP and QRM
Quality management is a wide-ranging concept covering all matters that individually or
collectively influence the quality of a product. Quality management, therefore, incorporates
16. GMP and other factors, including those outside the scope of this guide, such as product design
and development.
2.4 cGMP
GMP applies to the life-cycle stages from the manufacture of investigational medicinal products,
technology transfer, and commercial manufacturing, through to product discontinuation.
Components of cGMP
PREMISES.
The rooms are designed and constructed to minimize risks of errors and cross
contamination while promoting easy cleaning and maintenance.
Proper arrangement of a room and design will promote quality of final product since it
will be minimizing cross contamination. This can be seen on the epoxy floors used in the
facility which promote easy cleaning.
The design of the production area allows for unidirectional flow.
Double skinned windows in production area and all utility fixtures are fitted in to the wall
and ceiling. There is also a walk able ceiling used to do maintenance work like on
lighting.
The floor in production area is made of epoxy and the walls are painted with white poly
urethane coat that has antifungal properties.
There are no corners in the rooms or curved wall joints for easy cleaning.
PERSONNEL.
The element of personnel comprises majorly of hygiene, medical checkups, gowning procedures
and training of the workers in the facility .Since the workers are likely to get into contact with
the materials and products in the manufacture of drugs .The following procedures were followed
in the facility.
The facility has got an adequate number of qualified people with practical experiences
that are given initial training in GMP and continuous training.
17. There is restricted access to the production area.
Heads of production and quality control are independent of each other.
All personnel prior to and during employment undergo health examination.
Before moving from one area to another all personnel thoroughly disinfect their hands.
Adequate changing facilities with washrooms are available and a standard operating procedure is
followed.
EQUIPMENT
This aspect comprises of the machines and equipment that are used in the drug
manufacture. Characteristic properties that the material they are made of include:
Generally the equipment are made of materials that are generally non corrosive, non-
absorptive and nonabrasive in nature e.g. SS 316.
All the equipment are located, designed, constructed, adapted and maintained to suit the
operations to be carried out.
The design of the equipment allows for easy cleaning.
Moving parts of the machines are enclosed.
Equipment used for production is made of SS 316 for contact parts that has a mirror
finish and SS 304 for non-contact parts.
MATERIALS
The materials used in production are purchased from approved and certified suppliers. Before
use QC has to carry out tests to confirm their identity and quality standards. The materials are
stored in the required conditions as specified by the manufacturer. Material personnel contact is
minimized by laminar air flow unit during sampling and dispensing .The use of lifts also limits
personnel contact to the materials. The storage of the materials involves labels and status boards
for identity. All raw materials are procured from approved vendors and are quarantined
immediately after receipt until released by QC. There are adequate facilities for storage of the
raw materials and are segregated .A provision is available for cold storage.
18. 2.5 SELF INSPECTION:
Self-inspection is basically a method of objective overall review of operation on aspects that may
have on quality effect on quality assurance. In general, self-inspection aims at identifying
deficiencies in cGMP whether of critical, major or minor nature. Self-inspection is conducted by
designated competent persons from the company. Self-inspection program is conducted in order
to monitor the implementation and compliance with current GMP principles and to ensure that
the necessary corrective measures are taken.
Coverage of Self inspection:
The Self inspection team should carefully study every point in the GMP guidelines and drive
questionnaires fitted to the company needs. The following items should undergo self-inspection
so as to ensure GMPs in the premises as per WHO requirement.
Personnel
Premises and Equipment
Maintenance
Storage of starting and finished products
Production and in-process controls
Quality control
Documentation
Sanitation and Hygiene
Validation and revalidation program
Distribution
Product complaint and recall
Calibration of instruments
Labels control
Results of previous self-inspection and corrective action taken
Corrective Action:
Should be appropriate to correct deficiency
Must prevent re-occurrence
Must be completed in a timely manner
19. It should be documented and records maintained
Must be monitored
2.6 COMPLAINTS AND RECALLS:
A complaint is an expression of dissatisfaction conveyed to an organization about a product,
written, electronic or oral communication that alleges deficiencies related to the identity,
quantity, durability, safety, effectiveness or performance of a drug after it is released for
distribution.
CHANGE CONTROL
Any change has to go through a clear approval by the QA manager.
Change may be; Major (majorly affect other processes), Moderate (may or may not affect any
process. Minor (impact no change on process). The change may be process related or product
related. Change control goes through stages which include Initiation, approval, and
implementation.
2.7 VALIDATION
Involves establishing evidence which provides a high degree of assurance that a specific process
will consistently produce a product meeting its predetermined specifications and quality
attributes. Validation generally implies that a process, product or machine does what it’s
supposed to do .Validations are done after finalizing a formula for a product, processes, before or
after new drug application approval for example for a new drug product three batches are
validated before applying for marketing authorization.
The major aim of carrying out this process is to assure that products have identity, strength,
quality, and purity they are represented to possess (purport).
TYPES OF VALIDATION:
Process validation: ensures that a given process is capable of producing products that are
of the required standard
Prospective validation: which is done prior to distribution of the products
Concurrent validation: generation of validation data with normal production
20. Retrospective validation: validation which is done to products already in distribution
Cleaning validation; done to verify the effectiveness of cleaning procedure for removal
of the product residues, degradation products, preservatives, excipients and or cleaning
agents so that analytical monitoring may be reduced to a minimum in the routine phase.
DOCUMENTATION IN VALIDATION:
Validation MasterPlan:
It’s a document that summarizes the firms overall philosophy, intentions and approach to be used
for establishing performance adequacy. It is a clear concise reflection of the key elements of the
Validation program contains at least;-
A validation policy
Organizational structure of validation activities
Summary of facilities, systems, equipment and processes validated and to be validated
Documentation format (e.g. protocol and report format)
Planning and scheduling
Change control
References to existing documents.
The uses of the VMP include:
To know what validation program involves with respect to time, people and money and
to understand the necessity of the program
Helps Validation team to know their tasks and responsibilities
Helps GMP inspectors to understand a firm's approach to validation and the set up and
organization of all validation activities.
Capacity planning.
Validation protocol: a written plan stating how validation process will be conducted including
the test parameters, product characteristics, production equipment and the acceptance criteria.
21. Validation report: a written report on the validation activities, validation data and conclusions
drawn.
2.8 QUALIFICATION;
It’s like validation but applies to systems, equipment and facility area. Is an action of providing
documentation that premises, systems and equipment’s are properly installed, and/or work
correctly and lead to the expected results. Qualification is part of Validation process only that it
is always used for the equipment’s, utilities and system. It is also the initial step of validation
process. Validation is used for the processes. Qualification has been divided into the following
parts;
Designqualification (QC)
Installation qualification (IQ)
Performance qualification (PQ)
Operation qualification (OQ)
Qualification has got stages that include the following;
In case of new machines a process is passed through a process that involves a machine certifying
that a machine that is suitable for its function.
IQDQ PQOQ GMPcertification
DQURS SATFAT OQIQ PQ
22. User Requirement Specification: The Company makes URS that includes description of
equipment, GMP aspects, parts, capacity, speed, location suitability, details of utilities.
DesignQualification: Evidence that the equipment and process have been designed in
accordance with requirements of GMP. After manufacturer has received the user requirement
specifications, he sends a document with the design of the machine he can manufacture
depending on design sent.
Factory Acceptance Test: When the user has seen that the design can work for required
purpose, he sends a factory acceptance note to manufacturer, giving him a go ahead to
manufacture machine .Before machine taken to premises it’s then tested from the factory under
strict supervision by the company purchasing. The FAT is issued if it’s perfect and machine is
shipped.
SAT: Site Acceptance Test prepared by the company to ensure that the FAT, utilities required
for the equipment if any and prove that equipment meets requirement. This is done to ensure that
the machine is functioning properly at site of the user.
Installation qualification; provides documented evidence that premises, supporting utilities and
equipment have been built and installed in compliance with their specification.
Operation qualification: provides documented evidence that the operation of a machine
complies with the required specification. After installation the machine, it is first run on dry runs,
to check for its operation as specified by the manufacturer. It’s qualified for operation.
Performance qualification: Process/ equipment will consistently produce a product meeting its
predetermined specification and its quality attributes. A hand over certificate conducted during
the 1st three batches using placebo batch and product in the following combinations:
All three batches of placebo
One batch of placebo and two batches of the same product
One batch of placebo and two batches of different products (commercial)
Three batches of different products
The documents that are used in validations include
23. STANDARD OPERATING PROCEDURE
Logical sequence of events in instructional form of how, when, where and by whom an activity
is to be carried out .In the facility SOPs where found in all the cubicles hanged on the walls.
SOP consist of the following;
Examples of SOPs
SOP of SOPs
SOP of complaint handling and record
SOP of deviation handling
SOP of annual product quality review
SOP of recall procedure.
Etc.
2.9 DOCUMENTATION;
It’s an important aspect of cGMP. Importance of documentation is given below;
Ensure that there are specifications for all materials and methods of manufacture and
control.
Ensure all personnel know what to do and when to do it.
Ensure that authorized persons have all information necessary for release.
Provide audit trail.
To provide history of manufacture of a product.
TYPES OF DOCUMENTATION.
Labels, specifications and master formulae.
Batch processing and BPR.
SOPs.
24. 3 STORES
How goods move in facility
Production starts at stores and ends at stores. Before raw materials are bought .they source the
manufacturers who are to supply the factory with the materials. The approved manufacturers are
then placed on a list. The list is then sent to procurement to decide who to purchase from. Before
the use of materials they are stored in well configured areas for inspection and approval .The
storage of these materials is a responsibility of the stores department. The function of this
department is the reception of procured materials and finished materials. The materials are stored
in a way to ensure that there is no cross contamination .Before production or packing the various
departments send BMR or BPR respectively. These contain a description of how much is needed
for the activity to take place. If a certain material is out or almost out of stock. A requisition is
made and sent to procurement which spearheads the purchase of the material.
STORES ALSO HAS CERTAIN PRACTICES TO ENSURE cGMP:
They include the following
Storing items on mobile racks.
RECIEVING BAY
QUARANTINE
GOODS STORE
SAMPLING
AREA BY QC
APPROVED
GOODS STORE
DISPENSING
STORE
PRODUCTION
FINISHED
GOODS STORE
DOCUMENT
REVIEW
BATCH RELEASE
CERTIFICATE
DISPATCH
25. Preventing the items from getting into contact with the ground using the racks
Cleaning the floor regularly
Having separate sampling and dispensing rooms for both active and inactive ingredients
Documentation of the activities done.
Monitoring the conditions of the rooms since certain items require specific conditions.
Following the correct gowning procedures for activities like sampling and dispensing
Displaying SOPs around the different store areas
Using trolleys to carry materials instead of man
Control access is limited to most areas using a thumbprint, padlocks
Using double seal locks
Dispensing and sampling rooms have laminar air flows to prevent cross contamination
Stores is divided into 6 areas which include;
3.1 RECEIVING BAY AREA
Materials that have been purchased enter the facility through the receiving bay .The
receiving bay is divided into two areas .The packaging material and raw material receiving bay
.each receiving bay has a change room of its own. The doors at entrance to receiving bays have
air curtains to prevent mixing of inside and outside air.
3.2 RAW MATERIAL QUARANTINE AREA.
Before materials are used, they are quarantined for sampling tests .in order to determine their
quality. Tests include assay, if they pass the physical and chemical tests at QC. This area has a
sampling area for both active and inactive raw materials.
The materials under tests are labeled with an UNDER TEST label (yellow) and those awaiting
reanalysis have REANALYSIS label (red). The room is kept at a temperature of (2-25) º C and
RH of 45%-60%. The pressure is also monitored using manometer, while temperature and
humidity monitored by a hygrothermometer. The active materials and inactive materials include
3.3 SAMPLING AREA.
This area is used by QC department for the sampling process done for materials under test.
Whereas QC uses this area stores maintains it. The sampling areas include the inactive and active
26. sampling area. Each sampling area has its own change room .the materials are received into the
sampling areas through raw material pass box .The sampling unit is a class 5 ISO classified .It is
made of a laminar air flow unit .Sampling is done in the laminar air flow unit prevention of cross
contamination between the sampler and the material is achieved due to the unidirectional air
flow.
3.4 APPROVED RAW MATERIAL AREA.
When the material has passed the test carried out during sampling, it is given a PASSED LABEL
(green). These materials are then taken to the raw material approved area .They are then kept in
this area before dispensing. The materials are kept on a mobile rack system and the temperature
and humidity measured by hygrothermometer and pressure measured by nanometer. Some
Materials which require cool conditions are kept in cool walk in chamber .When excess material
was in the approved room due to the less space in the quarantine room, the yellow rope is
removed and replaced by a green rope. The materials are kept separated segregated batch wise as
pallets / item wise as pallets / shelf.
3.5 DISPENCING
Dispensing is done under ISO class 5 Reverse Laminar Air flow booth. Active and inactive are
dispensed separately. This is done after a requisition has been made by the department in need
3.6 PACKAGING MATERIAL STORES
This store is divided into two; primary packaging material store and tertiary, secondary store
.The tertiary and secondary material are stored in the same cubicle which has no ISO
classification. The packing materials in this area are kept off the floor on pallets and in a mobile
rack system
PRIMARY PACKING MATERIAL.
Primary packing material are material directly attached to drug .This cubicle contains a laminar
air flow unit and a mobile rack system. The materials are kept off the flow on mobile racks.
There are a variety of primary packing materials which include;
PVC ACLAR
FOIL
27. HDPE bottles
Caps
Procedure of receipt.
Has sections; - primary, secondary, and tertiary packing material store.
After receipt of these materials each is kept in its respective store where it’s first quarantined
until it passes QC tests then they are passed. Primary packing material must be sampled and
dispensed under a lamina air flow cabinet.
SECONDARY PACKING MATERIAL
Cartons
Enclosures
literature
Cotton
Silica gel
Labels
TERTIARY PACKING MATERIALS
Shippers
BOPP Tapes
Fitments
Labels
3.7 FINISHED GOODS STORE.
The finished pharmaceutical products are stored here before dispatch. Before dispatch the store
must first issue a batch release certificate. This area is involved in the storage of the finished
goods temporarily until the QC and QA tests are complete. If passed, the goods are then ready
for distribution. The finished goods are kept on a mobile rack system off the ground batch wise.
They are also kept on SS pallets together as a batch .The temperature and humidity are
monitored using a hygrothermometer and pressure using a manometer .temperature (19-25) º C
and RH (45-60) %. The goods can be attached with UNDER TEST and PASSED status boards.
28. 4 QUALITY CONTROL
Quality control is divided into two main departments’ chemistry and microbiology. Chemistry
department mainly deals with the active ingredients and some other tests like packaging
materials. Microbiology deals with the inactive and microbiological organisms this department
ensures that manufactured products, materials or performed services adhere to a defined set of
quality criteria or meets the requirements of client and also detect defects. The department
carries out chemical and physical analyses of different samples like
Water.
Air
Primary packaging materials
Raw materials.
Finished products
The instruments found in QC include;
Analytical Balance
an analytical balance is used to measure mass to a high degree of precision and accuracy. To
some the analytical balance may simply be known as a set of scales, but an analytical balance is
able to measure down to the ten thousandth of a gram. An analytical balance, also known as a
precision balance, it most often found in a laboratory setting and is used only with the most
meticulous of measurements. They require a draft-free location on a solid bench that is free of
vibrations. Some modern balances have built-in calibration masses to maintain accuracy.
pH Meter
a pH meter is an electronic instrument used for measuring the pH (acidity or alkalinity) of a
liquid (though special probes are sometimes used to measure the pH of semi-solid substances). A
probe is placed in a liquid, and it generates an electrical voltage that is converted to a logarithmic
pH reading. The pH scale range is 1 to 14.
Polarimeter
a polarimeter is a scientific instrument used to measure the angle of rotation caused by passing
polarized light through an optically active substance. Anisotropic crystalline solids, and samples
containing an excess of one enantiomer of a chiral molecule, can rotate the orientation of plane-
29. polarized light. Such substances are said to have optical activity. Measurement of this change in
polarization orientation is called polarimetry, and the measuring instrument is called a
polarimeter. These measurements are useful for studying the structure of anisotropic materials,
and for checking the purity of chiral mixtures.
• Isolating and identifying unknowns crystallized from various solvents or separated by high
performance liquid chromatography (HPLC).
• Evaluating and characterizing optically active compounds by measuring their specific rotation
and comparing this value with the theoretical values found in literature.
• Investigating kinetic reactions by measuring optical rotation as a function of time.
• Monitoring changes in concentration of an optically active component in a reaction mixture, as
in enzymatic cleavage.
• Distinguishing between optical isomers.
IR Moisture Balance:
A high performance compact, dependable Infra-red Moisture Balance for measurement of
moisture content of material not affected by radiation while losing water under of moisture
exposure to Infra-red radiation. IR moisture balance is an accurate method for moisture content
and dry weight analysis of a wide range of products and materials.
KF Titrator
Karl Fischer titration is a classic titration method in analytical chemistry that uses coulometric or
volumetric titration to determine trace amounts of water in a. KF titration
- is highly specific and precise
- covers a wide concentration range: from ppm up to 100%.
- has short determination times.
IR Spectrophoto Meter
It is used to measure the maximum absorption of infrared spectrum compound and the
determination of IR radiation.
Ultraviolet-Visible spectrophotometer
Ultraviolet–visible spectroscopy or ultraviolet-visible spectrophotometry (UV-Vis) refers to
30. absorption spectroscopy or reflectance spectroscopy in the ultraviolet-visible spectral region.
This means it uses light in the visible and adjacent (near-UV and near-infrared (NIR)) ranges.
UV/Vis spectroscopy is routinely used for the quantitative determination of different analytes,
such as transition metal ions, highly conjugated organic compounds, and biological
macromolecules. Determination is usually carried out in solutions.
• Solutions of transition metal ions can be colored (i.e., absorb visible light) because d electrons
within the metal atoms can be excited from one electronic state to another. The colour of metal
ion solutions is strongly affected by the presence of other species, such as certain anions or
ligands. For instance, the colour of a dilute solution of copper sulfate is a very light blue; adding
ammonia intensifies the colour and changes the wavelength of maximum absorption (λmax).
• While charge transfer complexes also give rise to colours, the colours are often too intense to
be used for quantitative measurement.
Particle counter
a particle counter is an instrument that detects and counts particles. By its very nature a particle
counter is a single particle counter, meaning it detects and counts particles one at a time. The
nature of particle counting is based upon either light scattering or light obscuration. A high
energy light source is used to illuminate the particle as it passes through the detection chamber.
The particle passes through the light source (typically a laser) and if light scattering is used, then
the redirected light is detected by a photo detector. Or if light blocking (obscuration) is used the
loss of light is detected. The amplitude of the light scattered or light blocked is measured and the
particle is counted and tabulated into standardized counting bins. The image to the right shows a
light scattering particle counter diagram.
Dissolution test apparatus
In the pharmaceutical industry, drug dissolution testing is routinely used to provide critical in
vitro drug release information for both quality control purposes, i.e., to assess batch-to-batch
consistency of solid oral dosage forms such as tablets, and drug development, i.e., to predict in
vivo drug release profiles. The designs of the dissolution apparatuses and the ways of operating
dissolution apparatuses have huge impacts on the hydrodynamics, thus the performances.
Disintegration test apparatus
it is used to measure the tablet disintegration time and subsequent drug dissolution.
31. Friability Test Apparatus
Tablet friability test apparatus are used for determination of durability of tablets at the time of
production. The apparatus is designed to provide the precise value of rate of abrasion and impact
hardness of the tablets. Friability is important since it affects in particle size distribution of
granules affecting compressibility into tablet, tablet weight variation, granule flowability.
Friability is determined carrying out Tumbler Test or using Friability Tester (RocheFriabilator)
and % loss is determined.
Hardness test facilities
It is to measure the hardness the tablet and it is essential to determine the disintegration and
dissolution of drug and efficient of drug.
High-performance liquid chromatography (HPLC)
High-performance liquid chromatography HPLC, is a chromatographic technique that can
separate a mixture of compounds and is used in quality control chemistry to identify, quantify
and purify the individual components of the mixture.
HPLC typically utilizes different types of stationary phases contained in columns, a pump that
moves the mobile phase and sample components through the column, and a detector to provide a
characteristic retention time for the analyte and an area count reflecting the amount of analyte
passing through the detector. HPLC is really the automation of traditional liquid chromatography
under conditions which provide for enhanced separations during shorter periods of time, utilizing
32. very small particles, small column diameters, and very high fluid pressures
HPLC is accomplished by injection of a small amount of liquid sample into a moving stream of
liquid (called the mobile phase) that passes through a column packed with particles of stationary
phase. Separation of a mixture into its components depends on different degrees of retention of
each component in the column. The extent to which a component is retained in the column is
determined by its partitioning between the liquid mobile phase and the stationary phase. In
HPLC this partitioning is affected by the relative solute/stationary phase and solute/mobile phase
interactions
These instruments are calibrated regularly monthly and annually using standard weights
The factors which influence the HPLC performance
Internal diameter of column
the smaller in diameter, the higher in sensitivity
Pump pressure
the higher in pressure, the higher in separation
Sample size
33. The polarity sample, solvent and column
Temperature
the higher in temperature, the higher in separation
To control the drug stability
Quantity of drug determination from pharmaceutical dosage forms
Quantity of drug determination from biological fluids, ex: blood glucose level
DEPARTMENTS OF QC
4.1 WET CHEMISTRY
The equipment used includes:
Dissolution tester;
Materials
Lumartem, Duovir-N
4.2 WEIGHING SECTION
The following instruments were seen in this section.
Analytical balance; for weighing material
Karl Fischer auto Titrator example Nevirapine, Lumartem tablets.
.HOT ZONE AREA.
Chemicals used here include;
Fuming chemicals for example HCl, H2SO4, HNO3, glacial acetic.
Triethtlemine GR-adjust pH of HPLC water.
Equipment used include;
Vacuum oven-drying of substances in absence of air
Muffles furnace-determine sulfated ash-corn starch.
Precision hot air oven-analysis of ox-disable substances in H2O.
Ultrasonic cleaner-dissolving substances.
34. Fuming hood –for safety from dangerous acids through absorption of fumes by use of
active carbon holding acids.
Heating mentle-boiling point
4.3 TITRATION and STANDARD AREA
This area consists the following instruments;
pH meter-determine pH purified water
Bio-containment work station –prepare a compensate sample.
Magnetic stirrer-dissolving substances
Conductivity meter-determines water conductivity
4.4 WASHING AREA
Glassware drying oven –drying
Water purification system –purifies water for HPLC.
Water bath-heating, evaporation and warming.
4.5 MICROBIOLOGY SECTION
Microbiology is under responsible for determining the microbial contamination in an
environment, raw materials and finished products.
It’s divided into five areas:
Preparatory area.
This is where activities are done in preparation for analysis. For example, sterilization of
equipment, media preparation among others.
Sterilization: this is done to kill all micro-organisms on the equipment to be used in the lab for
analysis.
There are two types of sterilization that are mainly used at Cipla QC.
Steam sterilization;
35. It is carried out using an autoclave. It’s carried out at 1210C for approximately 20 minutes.
Materials sterilized using this method are sensitive to high temperatures for example Glass
apparatus and equipment, dressings and fabrics and Plastic and rubber closures
Dry heat sterilization;
It uses a laboratory oven at 1600C for 2 hours. This method uses high temperatures and a high
penetrating power. Materials sterilized by this method are not sensitive to high temperatures and
include Glassware (sterilized up to 250° for 2 hours to effect depyrogenation)
Media preparation;
The process of preparation includes weighing the required amount and then adding a specified
volume of water.
Equipment present in the preparatory room includes;
Autoclave: For sterilization of media and other equipment used in the microbiology lab.
It’s also used for destruction of media before it’s released to the environment.
Weighing balance: for weighing media during media preparation.
pH meter: for measuring the pH of the media.
Oven: For sterilization of instruments sensitive to moist heat.
Incubator
Refrigerator
Hot air oven: for drying.
The types of analysis that occur in the microbiology laboratory include;
Water analysis: To identify or quantify any microorganisms present for example pseudomonas
aeroginosa, E.Coli, Salmonella, etc.
Micro testing room:
The area has laminar air flow. Hers a pass box foe passage of materials to and from the micro
testing room.
Incubation area:
36. Various incubators are present and they incubate different microorganisms. The incubators are at
different temperatures to favor growth of specific microbes for example:
40oC to 45oC for E.Coli.
35 to 37oC for pathogens.
25oC for fungi.
Culture handling room: there is a bio containment work station where procedures are carried out
from. It has vertical laminar airflow to protect personnel. It has a pass box where materials are
passed to avoid cross contamination.
Activities done in this area include; water analysis which is done under laminar air flow and
dispensing of culture media.
TYPES OF MEDIA AND THEIR USES.
There are two types of media present in the microbiology section at Cipla QC; that is liquid
media (broth) and solid media (agar). Examples of media present in the lab include;
Media Use
deoxycholate citrate Agar Selective for salmonella & shigella species
EMB Agar (Levine) Isolation enumeration & differentiation of
Columbian Agar Detect clostridium sporogenes from pharmaceuticals
Bismuth sulphate Agar medium Selective isolation of salmonella from faces ,urine
Brilliant green agar base Selective isolation of salmonella other than s. typhi
Nutrient broth medium Sterility testing for aerobes
Pseudomonas agar (for fluorescing ) Fluorescein production by pseudomonas
SCM (Broth medium) General purpose medium for microbes
Reinforced clostridia agar Sterility testing for moulds & lower bacteria
clostridia & other aerobes.
Sabourand dextrose Agar Cultivation of yeast moulds & acidified
microorganism
37. Triple sugar iron agar Identification of gram negative enteric bacilli on the
basis of dextrose, lactose & sucrose, fermentation
&H2S production
Yeast maltose broth Acidify for selective medium
Vogel Johnson agar base yeast, mould, & aciduric MOs staph aureus
Yeast maltose agar Isolation & cultivation of yeasts, moulds & other
aciduric micro organism
38. 5 PRODUCTION
After the dispensing of materials from the raw material approved room in response to the work
order, they are taken to the production department. Production department is made of
granulation, compression, coating and packing sections. The flow of materials in production is
uni-flow from granulation, compression, and coating and finally to packing section .The
production department is completely involved in the drugs manufacturing process .During the
process manufacture IPQC checks are carried out to ensure quality in process of production and
prevent batch failure. When raw materials are required in the production of drugs, the production
department makes an order to the stores department which them dispenses off the material. In
case of excess raw materials. The materials are returned. In case of less raw materials an extra
material memo is made .the following products are produced
5.1 PRODUCTS OF CIPLAQCIL
ARVS
DRUG ACTIVE INGREDIENTS
Effavir 600 Efavirenz 600mg
Duovir Zidovudine USP 300mg,
Lamivudine USP 150mg
Duovir-N Zidovudine USP 300mg,
Lamivudine USP 150mg,
Nevirapine USP 200mg
Nevimune Nevirapine USP 200mg
Duomune Tenofovir
DisoproxilFumarate 300mg
Lamivudine USP 300mg
Trioday Lamivudine 300mg
Tenofovir DisoproxilFumarate 300mg
Efavirenz 600mg
Texavir Tenofovir 300mg
39. ACTs
DRUG ACTIVE INGREDIENTS
Lumartem Lumefantrine 120mg
ArtmetherPhint 20mg
5.2 GRANULATION
Granulation is the process of forming granules from powder particles. The small powder
particles are made to adhere to make bigger granules .The powder particles are made to adhere
for many reasons which include
Tablets are the most common drug dosage form today, and thus granulation, which allows
primary powder particles to adhere and form granules, is one of the most important unit
operations in drug manufacturing. Understanding granulation grows more complex each year.
Particle-bonding Mechanisms
a) Adhesion and cohesion forces in immobile films. If sufficient liquid is present in a powder to
form a thin, immobile layer, there will be an increase in contact area between particles. The bond
strength between particles will increase, as the Van der Waals forces of attraction are
proportional to the particle diameter and inversely proportional to the square of the distance of
separation.
b) Interfacial forces in mobile liquid films. During wet granulation, liquid is added to the powder
mix and distributed as films around and between the particles. There are three states of water
distribution between particles. At low moisture levels, the pendular state, particles are held
together by surface tension forces of the liquid/air interface and the hydrostatic suction pressure
in the liquid bridge.
When all the air has been displaced from between the particles, the capillary state is reached, and
the particles are held by capillary suction at the liquid/air interface. The funicular state represents
an intermediate stage between the pendular and capillary states. Moist granule tensile strength
increases about three times between the pendular and the capillary state. These wet bridges are,
40. however, a prerequisite for the formation of solid bridges formed by adhesives present in the
liquid, or by materials that dissolve in the granulating liquid.
Solid bridges can be formed in two ways:
Hardening binders. When an adhesive is included in the granulating solvent it forms liquid
bridges, and the adhesive will harden or crystallize on drying to form solid bridges to bind the
particles.
Crystallization of dissolved substances. The solvent used to mass the powder during wet
granulation may partially dissolve one of the powdered ingredients. When the granules are dried,
crystallization of this material will take place and the dissolved substance then acts as a
hardening binder.
c) Attractive forces between solid particles. In the absence of liquids and solid bridges formed by
binding agents, there are two types of attractive force that can operate between particles in
pharmaceutical systems, electrostatic forces and Van der Waals forces. Van der Waals forces are
about four orders of magnitude greater than electrostatic and add to the strength of granules
produced by dry granulation.
Mechanisms of Granule Formation
a) Nucleation. Granulation starts with particle-particle contact and adhesion due to liquid
bridges. A number of particles will join to form the pendular state. Further agitation densifies the
pendular bodies to form the capillary state, and these bodies act as nuclei for further granule
growth.
b) Transition. Nuclei can grow in two possible ways: either single particles can be added to the
nuclei by pendular bridges, or two or more nuclei may combine. The combined nuclei will be
reshaped by the agitation of the bed. This stage is characterized by the presence of a large
number of small granules with a fairly wide size distribution.
41. c) Ball Growth. If agitation is continued, granule coalescence will continue and produce an
unusable, over-massed system, although this is dependent upon the amount of liquid added and
the properties of the material being granulated.
There are four possible mechanisms of ball growth, which are illustrated in the illustration
Coalescence. Two or more granules join to form a larger granule.
Breakage. Granules break into fragments which adhere to other granules, forming a layer
of material over the surviving granule.
Layering. When a second batch of powder mix is added to a bed of granules, the powder
will adhere to the granules, forming a layer over the surface and increasing the granule
size.
Abrasion Transfer. Agitation of the granule bed leads to the attrition of material from
granules. This abraded material adheres to other granules.
Granulation Methods
Dry Granulation. This requires two pieces of equipment, a machine for compressing the dry
powders into compacts or flakes, and a mill for breaking up these intermediate products into
granules. The dry method may be used for drugs that do not compress well after wet granulation,
or those which are sensitive to moisture/water.
Wet Granulation. In this method, the wet mass is forced through a sieve to produce wet
granules which are then dried. A subsequent screening stage breaks agglomerates of granules.
Organic solvents are used when water-sensitive drugs are processed, as an alternative to dry
granulation, or when a rapid drying time is required. Because direct compressing is not the best
technology for many active substances, wet granulation is still a preferred method. Even if the
active substance is sensitive to hydrolysis, modern equipment (e.g., a fluidized bed) eliminates
all problems in wet granulation.
Factors Affecting Granulation Methods
Liquid Requirement. High-shear mixers may exhibit a narrow margin between the liquid
required to obtain granule growth and the amount that results in an over-wetted mass.
Because of the intensive wet massing and densification of the granules, less liquid is
42. normally required with high- than with low-shear mixers .In addition, impeller rotation
speed influences the liquid requirements, as does evaporation of the solvent, usually
water, in the binder solution. Especially with high-shear mixers, intense agitation results
in a temperature rise and loss of solvent by evaporation.
Effects of Raw Material Properties. The following properties influence granule formation and
growth:
Contact angle of the binder liquid to the solids
Solubility of the particles in the binder liquid
Mean particle size and size distribution of the solids
Particle shape and surface morphology
Packing properties of the solids
Raw materials must have good wetting properties if there is to be uniform liquid
distribution and, hence, controlled granule growth. The smaller the particle size of the
raw material, the more binder liquid required.
Binder Properties
Binder Concentration. The binder forms an internal matrix; consequently, the granule strength
and tablet strength increase as binder concentration increases. Mechanical Properties of Binder.
The mechanical properties of the binder determine binder strength and deformation behavior of
the binder matrix.
Properties of Drug and Other Excipients in the Formulation
Wet granulation depends upon wetting of powder by the binder solution, surface tension of
lenticular bridge films formed and solution viscosity. Binder Distribution. The distribution
influences the binder’s ability to produce strong and non-friable granules. The processing
method used to distribute the binder influences binder efficiency.
To improve the particle size distribution so as to improve the compressibility.
Prevent segregation of the constituents of the mix
Improve flow properties of the mix
43. Reduce hazard of toxic materials associated with handling.
Reduce possibility of caking with hygroscopic material
Improve drug release properties.
It makes occupation of less volume per weight, hence easy handling.
CONDITIONS
The granulation area is a critical area, with the temperatures and relative humidity monitored and
kept within the required limits .Temperature (19-22 ºc) and relative humidity (45-
60%).Deviations from the required limits can lead to reduced quality of the end product. It is
mainly applied to heat labile and moisture sensitive materials like Duovir (Lamivudine and
Zidovudine).
The granulation section has three granulation cubicles, granulation I, II, III.
Each cubicle is divided into a binder solution preparation room, washing area and an area were
sifting, sizing and granulation occur.
5.3 BLENDING
This is done using an octagonal blender after line clearance has been done. Manufacturing
process containers are first re-weighed and then attached to the blender mouth. The blender is
then rotated 180◦ to load the granules into the octagonal blender a process known as charging,
after the blender is rotated back to its normal position and the MIPC is disconnected. This is
repeated until all the granules have been loaded to the maximum capacity of the blender.
Lubricants such as magnesium stearate are also added. The blender is then set to rotate through
360◦ at a specified rpm. After blending, the granules are offloaded into MIPCs which are first
tared and the re-weighed with the blend and stored in the bulk store according to batch in lines,
where they are later picked for compression into tablets
MACHINES USED IN GRANULATION
Rapid Mixer Granulator
Works on the principle of high shear to achieve only mixing and granulation of the powders.
This mixer uses a highly viscous binder, it’s filled by SS bins for both the binder and powder
44. using an elevator, the mixer doesn’t dry and after granulation its products are taken to the FBE
for drying. It comprises of lid tighten clamps, bowl lid, agitator, chopper, binder/material charge
port, air vent, neoprene gasket, discharge port, chopper motor cover, plat form, control panel and
view window. The agitator helps uniform mixing, and a high speed chopper slices the lumps to
form smaller granules. Some of the raw materials used here include those of lumefantrine and
Efavirenz
Fluid Bed Equipment
This is used for granulation, drying, mixing and also coating of pellets. The raw material for
granulation is fed into the FBE by an evacuator pipe from IPCs after it has been re-verified
(label, weight, batch, texture). Hot air at high pressure is let into the equipment via the inlet pipe
to the lower plenum and then through the bowl sieve to the product container, and causes free
flow of the powders, the powders are first mixed and pre-heated ( up to 36-400C) to ensure
uniform mixing with the other inactive and create conditions for adding of binder for
approximately 5 minutes, after a peristaltic pump pumps a less viscous binder from a can and it
passes through a spray gun with 1mm nozzles and it continuously wets the powder as mixing is
continuously done.
The fluidized material is kept within the expansion chamber by the help of a finger bag which
allows only air to pass through and increases the surface area for mixing, drying is effected by
heat exchange between the hot air and the wet granules. The FBE has inflatable gaskets that
ensure that pressure is not lost to the outside during operation, exhaust and product temperature
is monitored throughout the process every after 10 minutes, if it is low it means that the material
is wet thus after binder spraying has been done, the material is dried. The material is sampled
through the sampling port (at specified temperature) and analyzed for loss on drying in intervals.
If LOD is in specified limits then drying is stopped and the formed granules are removed. The
material is then sized and milled and sent to blending after it has been re-weighed. Some of the
parts include; inlet air ducting, expansion chamber, lower plenum, explosion flap duct, product
container, spring tension, bowl sieve, SS supports, pneumatic control panel, inflatable gaskets,
neoprene gaskets, bull eye windows, filter bag assembly, spray gun, view window, control panel
and the peristaltic pump.
45. Vibrator sifter
This helps in material sifting, uses vibratory and gyratory motion as it causes vibration and the
particles of different sizes pass through the sieve from the upper hopper to the lower hopper and
re-collected. Depending on the material, sieves of different mesh sizes are used. The sizes of
sieves used are determined by the number of holes per linear inch. Determining of the sieve
integrity is one first essential step done before sifting using a dyner scan. It has various parts
including, sifter body, and wheel lid, upper hopper, lower hopper, and stainless steel clamp, sifter
hood, holding ring, neoprene gasket, sieves, control panel, electric cable and main body. The
neoprene gasket helps in the reduction of noise when vibrating.
PURPOSE OF SIFTING
obtain uniform particle size powder of desired range
check for any foreign matter which may come along with raw material
magnetic screens are provided at outlet of sifter to check and hold metal particles as most
of bulk drugs are synthesized, processed in mild steel reactors thus chances of steel, rust
particles
Raw materials from sifting area are then sent to granulation hall via pass box. Here binder
preparation occurs.
Multmill
Helps in the sizing of clamps of powders and granules that can’t pass through the sifter it has
various parts including ; pulley housing and cover, blade stud, wing nuts rotor, size reduction
chamber, hopper, base plate, gasket, control panel, electric cable, agitator and wheels. The
cleaning of the machine is similar to that of the vibrator sifter.
Roll compactor
This machine is used for dry granulation. It has a sieve in it and it only compacts and sifts at the
same time to make granule that pass through the sieve and collected through the lower hopper.
It’s made of two rolls rotating in different directions which allows for compression of the sifted
powder particles in between the rolls and this coupled with a vacuum pressure which leads to
flake formation.
46. Steam kettle.
This is used in preparation of the binder.
Octagonal blender
It rotates and mixes the contents using shear mixing. It has got baffles to aid this process. Its
speed is controlled using a programmable logic controller. Its main function is to blend and
lubricate
Weighing balance
This is used to tare cans, measure granules and also verify weights of raw materials before they
are granulated. The balance is calibrated by to forms
IN-PROCESS CHECKS AT GRANULATION
These include;-
Tap density- use of tap density apparatus/tester to determine bulk and tap density.
Moisture content- done using IR moisture analyzer
Percentage fines-using a sieve shaker.
Loss on drying
CLEANING PROCEDURE FOR EQUIPMENTS
Generally flush with portable water then apply detergent then rinse with portable water, flush
with purified water and finally dry using compressed air.
5.4 COMPRESSION
Compression is a process of tablet formation from granules with aid of compression force
through the usage of compression machine. The tools used for compression are Punches and dies
(kept in tool room). The die determines the diameter of the tablet. Machinery classification is
dependent on the following accepts
Rotation; single rotation and double rotation.
The machine used is called a double rotary machine.
47. Illustration of set up of compression apparatus
The components of the double rotary compression machine include;
Feed frame /force feeder; Holds the granule on turret so they fill the die bore.
Cam tracks; Lift upper punch and lower punch during cycle as required.
Pre compression blades; Give granules an initial tamping force to remove as much air as
possible before final compression.
Main compression rollers; Apply the full pre the set pressure on punches for final
compression of tablets.
Take off blade; Is fitted in front of the feeder frame to scrap the tablet off lower punch
tip
Ejection cam; Guides the lower punch upwards during the ejection stage. It is adjustable
to ensure smooth ejection without damaging tablets.
Hopper; this is where the granules are introduced into the machine.
Compression process
The compression process involves a series of stages.
Filling
The filling stage of the tablet compression process involves transfer of raw materials into
position for tablet compression. These raw materials have undergone prior processing by wet
granulation, dry granulation (roller compaction), sizing, or other processes. The final formulation
is then blended to yield a homogeneous blend. The blend then flows to the compressing machine
punch-die cavity. The punch-die cavity is composed of punch die and lower punch. The position
of the lower punch within the die determines the volume of the punch-die cavity. This volume
must be appropriately sized for the weight of granulation to be compressed into tablets. The
granulation is overfilled on the die table (turret) to ensure complete filling of the punch-die
cavity volume.
compression machine deduster metal detector MIPC
48. Metering
The metering stage of the tablet compressing process involves removal of excess granulation
from the compressing machine. This stage enables the exact weight (volume) of granulation to
be compressed into tablets. The exact weight of granulation is controlled by the height of the
lower punch in the die. The height of the lower punch is controlled by the metering cam (also
called the dosage cam). The lower punch is raised to the appropriate level in the die to provide
the exact weight of granulation in the punch-die cavity. The excess granulation is scraped from
the surface of the die table. The metering stage is similar to the method used to measure flour
when baking a cake. A measuring cup is first over-filled with flour; then a knife is used to scrape
off the excess. The exact amount of flour is then left in the measuring cup.
Compression
The compression stage of the tablet compressing process forms the tablet. This stage involves
bringing together the upper and lower punches under pressure within the die to form the tablet.
As the punches enter the compressing stage, the upper and lower punches move between two
large wheels called pressure rolls. These pressure rolls push the punches together to form the
tablet. The distance between the upper and lower punches determines the thickness and the
hardness of the tablet. When the punches are close together, a thin and hard tablet is created.
When the punches are farther apart, the tablet made is softer and thicker. The proper balance of
thickness and hardness determines the optimum roll distance for any specific product. These
adjustments are made while keeping the tablet weight constant.
Ejection
The ejection stage of the tablet compressing process involves removal of the tablet from the
lower punch-die station. In this stage, the upper punch retracts from the die cavity and rises
above the turret table. Then the lower punch rises in the die, which in turn pushes the tablet
upward to the top surface of the die table and out of the die cavity. A scraper (also called takeoff
scraper or tablet rake-off) then pushes the tablet off the die table away from the compressing
machine into the collection container.
TYPES OF TOOLING AND STATIONS;
49. Machinery classification is dependent on the following accepts
Rotation; single rotation and double rotation
Tooling refers to the diameter of the punches. B-type is for small tablets and is used to compress
LUMARTEM tablets and D- type which has a larger diameter of about 16mm and is used for
DUOVIR-N, DUOVIR and EFAVIR.
STATIONS.
This classification consists of the number of punches the machine has. The forms include 37, 45,
49, 55, 65 stations.
In case the machine is double rotary then this means it compresses twice the number of tablets
per rotation i.e. 37 station produces 37 x 2 = 74 tablets per rotation
Tooling refers to the diameter of the punches .B –type is for compressing lumartem tablets whilst
D-type for Duovir-N, Duovir, Effavir.
Type Die diameter Punch diameter machine Stations
D-tooling 38.1mm 25.4mm Cadpress iv 45
B-tooling 30.1mm 19mm Cadpress iv 55
BB-tooling 24mm 19mm Cadpress ii 45
TABLET PROBLEMS DURING COMPRESSION
Tablet defects POSSIBLE CAUSES
TOOLING RELATED PRESS RELATED FORMULATION
RELATED
Weight variation Inconsistency working height of the
Lower punch.
Jammed Lower punch. Granules not flowing
freely.
50. Thickness variation Inconsistency working height of the
Lower punch.
Inconsistency of the
Upper punch working
height.
Pressure roller
jumping.
Capping Air entrapment. Incorrect ejection setting. Use of pre-compressed
granules.
Sticking and picking Poor finish on punch cavity. Picking bore zones on
embossing.
Sticking formula.
High moisture content.
IN-PROCESS CHECKS CARRIED OUT DURING
COMPRESSION AND INSTRUMENTS
punch size the diameter
upper punch description circular and has an embossing of UG
lower punch description plane and circular
Standard Compression weight should be within limits
Hardness carried on tablets from both sides of the machine i.e. right and left side
TESTS CARRIED OUT
DISINTERGRATION TEST
This test is used to mimic the conditions in the human stomach where the time taken for a tablet
to completely disintegrate is noted .the instrument used is the disintegration tester and the drug is
expected to have disintegration time less than 15 minutes.
The apparatus is set at 37◦C and the time taken to disintegrate is read off from the timer display.
The water in the water bath is changed weekly.
HARDNESS TEST
51. This is done to determine the hardness of a tablet by use of the ERWEKA HARDNESS
TESTER. This instrument can also determine the diameter and thickness of the tablet .
First switch on tester then zero it. Select measure option on LCD, place the tablets in the stations
provided then the analysis process begins and results for thickness, diameter and hardness are
displayed on the screen. Enter product details and start. Then view results
FRIABILITY TEST
This instrument is used to determine the friability of a drug .This test is used to determine how
well a drug can sustain impaction forces during the process of transportation from one place to
another.
WEIGHING BALANCE
This instrument is used for group weights, individual weights. Individual weights are taken for
50 tablets from each side of the machine (Left Hand Side and Right Hand Side).
VERNIER CALLIPER,
This instrument is used to determine thickness, width and length .The digital Vernier caliper is
connected to the online recording system.
MACHINES USED IN COMPRESSION
These include
Tablet press-works on principle of particle compaction.
Deduster-operates on principle of spiral vibration and size exclusion. Has a mortar that
vibrates creating a suction force that enables powder dust to separates from tablet.
Metal detector-works on principle of magnetic attraction. A large magnetic field is set up
through which tablets are passed. Each tablet containing a metal component is attracted
and is not released due to eddy currents. Metal components detected include SS, ferrous
and nonferrous.
52. 5.5 COATING
Coating is the process of enclosing the tablet core with a polymer film or a sugar base. This is
the addition of a surface coat on the tablet.
Common pharmaceutical technique of applying a thin polymer based film to a tablet. Major
techniques include sugar-coating, film-coating, enteric –coating.
IMPORTANCES OF COATING
Tablets are coated for different reasons which include;
Masking the bitter test and bad smell of the active ingredient.
For functional purposes such as controlled release of the drug.
Provide physical and chemical protection for the drug from atmospheric effects such as
temperature, humidity and light.
Protect drug from gastric environment of stomach with acid resistant coating.
To incorporate another drug or formula adjuvant in the coating.
Improve appearance by use of special colors...
There are different types of coating which include;
Sugar coating.
Steps in sugar coating;
Multiple applications of syrup containing colour are required, water-soluble dyes or water-
insoluble lakes are used. Finally wax is applied in rolling pans.
Film coating
53. Preferred method which applies a thin, uniform coating on tablets.
Steps in film coating
The Suspension is prepared according to the SOP, and depending on the product to be coated,
then checking and setting of spray pattern of the machine. Tablet loading are loaded by the
operators in the machine. This is followed by preheating of tablets for five minutes before spray
is turned on. Tablets are sprayed using the coating suspension a defined rate as per SOP. Tablets
are dried after the specified period of coating. Finally unloading of tablets by the operators in the
MIPCs.
Functional coating.
This can include coating for slow release, enteric coating.
NOTE: Sugar coating involves use of a sucrose based solution while film and functional coating
involves use of suitable polymer which forms a thin film around the tablet core. At Ciplaqcil,
some of the tablets are film coated.
Components of a film coat
Solvent; IPA, Methylene Chloride
Plasticizers; poly ethylene glycol
Opacifier
Film former; methyl cellulose
Colorants
Opadry a raw material that contains all the required materials may be used.
Equipment for coating;
Neocota machine
GCsmart pam Glatt
PREPARATION OF COATING SOLUTION
54. Opardy yellow powder (1kgs) is placed in SPV, then a known amount of purified water is added
and mixture thoroughly mixed for 45 minutes. Final solution is sieved to remove solid particles
that did not dissolve.
Film-coating is a single stage automated process highly adaptable to GMP. A suitable polymer is
used to form a thin film around tablet core. Film coated tablets retain contour of original core in
case the coating is translucent, have 2-3% weight increase, logo or break lines. Coating occurs by
a spray process. Tablets on perforated coating pan are sprayed with coating suspension whilst
pan is rotating. Baffles ensure each is coated.
Parameters checked include product and exhaust temperature, spray rate, spray pattern,
atomization. In –process checks done include disintegration test, appearance of coated tablets,
group weight /individual rise, thickness test, loss on drying.
In process checks include
Appearance
Group weight and individual weight variation
Loss on Drying
Disintegration time
COATING DEFECTS
Reject Cause Solution
Tablet to tablet color
variation
Migration of coloured
components within tablet core
into the coating
use a coating in which the
components of the tablet core are
insoluble
Cracking Insufficient plasticizer Increase plasticizer
Edge chipping/erosion Low mechanical strength Increase the compression pressure
Core erosion Pan speed is too high Optimize speed of pan.
55. Orange peel roughness Viscosity is too high Increasing the spray rate and
decreasing the air temperature
Peeling Low mechanical strength Increase compression pressure
Twinning Spray rate too high Reduction of spray rate
Picking/sticking Inadequate drying Proper drying
56. 6 ENGINEERING
This department is located outside the facilities main building and its main purpose is to manage
and control the utilities used by the facility. It consists of various equipment aimed at providing
the optimal working condition. It helps to control the temperature and relative humidity inside
the facility premises. This is very important because the environmental conditions required
during the different stages of production vary depending on the type of product. The different
machinery found in this department include, Air compressor, Boilers, Chillers. The Engineering
department has the following sections.
Boiler room
Air compressor room
Chillers
Service floor (HVAC)
Effluent Treatment Plan (ETP)
Engineering Offices and Workshop
AIR COMPRESSOR;
For formation of purified air that is used in various processes during production like during
functioning of the FBE. Types of the air compressors.
Piston air compressors.
Screw air compressors.
The latter is preferred in the pharmaceutical industries because is oil free hence no incidences of
production of moisture that can interfere with the production process.
Procedure for purification
57. 6.1 BOILERS
Boilers are pressure vessels designed to heat water or produce steam, which can then be used to
provide space heating and/or service water heating to a building. In most commercial building
heating applications, the heating source in the boiler is a natural gas fired burner. Oil fired
burners and electric resistance heaters can be used as well. Steam is preferred over hot water in
some applications, including absorption cooling, kitchens, laundries, sterilizers, and steam driven
equipment. Boilers have several strengths that have made them a common feature of buildings.
They have a long life, can achieve efficiencies up to 95% or greater, provide an effective method
of heating a building, andin the case of steam systems, require little or no pumping energy.
How Boilers Work
Oil fired boilers use controlled combustion of the fuel to heat water. The key boiler components
involved in this process are the burner, combustion chamber, heat exchanger, and controls. The
burner mixes the fuel and oxygen together and, with the assistance of an ignition device,
provides a platform for combustion. This combustion takes place in the combustion chamber,
and the heat that it generates is transferred to the water through the heat exchanger. Controls
regulate the ignition, burner firing rate, fuel supply, air supply, exhaust draft, water temperature,
steam pressure, and boiler pressure. Hot water produced by a boiler is pumped through pipes
and delivered to equipment throughout the building, which can include hot water coils in air
handling units, service hot water heating equipment, and terminal units. Steam boilers produce
steam that flows through pipes from areas of high pressure to areas of low pressure, unaided by
an external energy source such as a pump. Steam utilized for heating can be directly utilized by
steam using equipment or can provide heat through a heat exchanger that supplies hot water to
the equipment. Pressure vessel integrity, checking of safety relief valves, water cutoff devices
and proper float operation, gauges and water level indicators are inspected. The boiler’s fuel and
airfrom
environment
filtration
low pressure
area
intercooler high pressure
compartmentafter coolerdrierstorage tank
to different areas
at different
velocity
58. burner system requires proper inspection and maintenance to ensure efficient operation, heat
transfer and correct flame detection.
6.2 CHILLER
Provide cold water from the chillers used in the cold water coil and the air from the compressor.
They are used to provide cold water which is used in reducing temperature of a cubicle through
HVAC system. When there is a change is relative humidity and temperature the level of cold
water given is changed to fit the conditions required i.e. increased cold water when lower
temperatures are required.
Operation
A vapor-compression chiller consists of four primary components of the vapor-compression
refrigeration cycle. They include a compressor, evaporator, condenser and a metering device.
Vapor-compression chillers typically utilize HCFC or CFC refrigerants to achieve a refrigeration
effect. Compressors are the driving force in a vapor-compression chiller and act as a pump for
the refrigerant. Compressed refrigerant gas is sent from the compressor to a condenser unit that
rejects the heat energy from the refrigerant to cooling water or air outside of the system. The
transfer of heat allows the refrigerant gas to condense into a liquid which is then sent to a
metering device. The metering device restricts the flow of liquid refrigerant which causes a drop
in pressure. The drop in pressure causes the warm refrigerant liquid to change phase from liquid
to gas and in doing so absorbs heat from the water to be cooled due to adiabatic flash
evaporation. The metering device is positioned so that the expanding refrigerant gas is contained
within the evaporator, transferring the heat energy from the water to be cooled into the
refrigerant gas. The warm refrigerant gas is then sent back to the compressor to start the cycle
over again and the newly chilled water in the separate loop can now be used for cooling.
6.3 HVAC system
While there are many functions that a HVAC system serves, the primary function is to maintain
a comfortable temperature in every room. This is done by the regulation of humidity, air flow, as
well as temperature so that these parameters stay within acceptable limits. While this makes
staying indoors comfortable, it also ensures that inhabitants do not suffer from health risks that
59. reside in the categories of excessive fatigue, draining out, heat strokes and hypothermia. HVAC,
as the name suggests, has three primary functions, they are:
Heating: HVAC serves the function of heating, this really could be the difference
between life and death. When it is literally freezing outside, you need a system that keeps
you warm and if it does it in a uniform manner, then all the more better and an HVAC
system does. Heating can be achieved through local as well as central heaters.
Central heating systems tend to be more cost effective and are made up of furnaces,
heating pumps, and radiators.
Ventilation: The V in HVAC stands for ventilation which pertains to the movement of air
in the home. Controlling the air flow allows the cleansing of the atmosphere indoors so
that unnecessary carbon dioxide can be carted out and the oxygen let in. Not only does
this aid breathing but it also aids in the prevention of air borne diseases and allergies
Air Conditioning: An air conditioning system may be one comprising of several window
machines or one central system. Dirty air ducts will need to be cleared immediately so
that no pathogens thrive and are living in it
6.4 ETP
a process to convert wastewater - which is water no longer needed or suitable for its most recent
use - into an effluent that can be either returned to the water cycle with minimal environmental
issues or reused. Waste from any industry should be treated before being released to the
environment. Waste from industries such as pharmaceutical industries can cause harm to the
environment if let out untreated. There wastes contain toxic substances which when released
contaminate or pollute both water and air. The main use of the ETP system is to treat waste
released by the facility. The ETP is located outside the facility approximately 400 meters to
prevent contamination .There are two types of waste treated by the ETP, which are domestic
waste which contains water from wash rooms, kitchen and industrial waste which contains waste
that was in direct contact with the product. After treatment the water is tested for different
parameters before releasing it to the Environment.
6.5 WATER TREATMENT
Water quality affects every operational aspect for manufacturers of pharmaceuticals. The raw
water obtained by the facility passes through multiple stages in the process of purification .The
60. purification is used to remove contaminants like; inorganic compounds, .organic compounds,
solids, gases, microorganisms.
The source of raw water is borehole and NWSC (National water and Sewerage Corporation).
The types of water used at QCIL are purified and portable water.
The main source of raw water is national water and sewerage cooperation which supplies the
portable water. The portable water undergoes the following stages in order to achieve purity.
STAGES OF WATER TREATMENT AND PURIFICATION
The pretreatment unit consists of;
MGF – for filtration
Softener –Removes hardness
Ultra filtration –Reduces the SDI (silt density index)
SMBS (sodium metabisulphite) - to neutralize free chlorine.
Chlorine dosing done using sodium hypochlorite (3ppm). MGF consists of sand media,
gravels, pebbles, corax, silex, fine corax and fine silex. The softener removes hardness. Ultra
filtration reduces SDI.Ultra filtration tank dosed with SMB which neutralizes free chlorine.
Permanent hardness is removed by backwashing / ion exchange.
Dosing with chlorine.
Chlorine kills off all the susceptible microorganisms.
Filtration.
This is done using a multi-grade filter.
The filter aids the removal of particulate matter.
SOFTENER UNIT
RAW WATER PRETREATMENT GENERATION
STORAGE AND
DISTRIBUTION
61. A water-softening system removes calcium and magnesium ions from hard water and replaces
them with sodium ions. Calcium and magnesium ions interfere with the action of household
soaps and detergents, but sodium does not. The water-softening process thus helps detergents to
more effectively remove dirt and oils from clothing and dishes. The pump house contains several
cubic feet of porous plastic resin covered with molecules that attract and bind to positive ions
dissolved in the water. Normally, sodium positive ions coat the resin, but as water flows over the
resin the naturally occurring calcium and magnesium positive ions that exist in hard water stick
to the resin. This releases sodium ions into the water in order to maintain a balance of electrical
charge on the resin. Gradually, most of the sodium ions are released into the plant water, and the
resin becomes saturated with calcium and magnesium ions. Every few days, the unit must renew
the resin by rinsing it with a concentrated solution of saltwater (sodium chloride), usually in the
middle of the night. The high concentration of sodium ions in the salty water displaces the
calcium and magnesium ions the resin, and the resin becomes once again covered with sodium
ions. The salty rinse water, calcium and magnesium ions are flushed down the drain, and the
system resumes normal operation. (Every so often it is necessary to add a bag of sodium chloride
salt to the softener unit to prepare this salty rinse water.)
ULTRAFILTRATION UNIT
This unit is used to filter off particulate matter, colloidal impurities, silt and microbes and to
reduce the silt density index to <3.
Consists of membrane of 0.02μ,5μ cartridge pre-filter which polishes the water particulate matter
which cannot be removed by MGF , a plate type heat exchanger which ensures transferred water
is NMT 25OC to avoid damaging the RO membrane.
Backwash is done every 1hour while disinfection is done after every 30 cycles using sodium
Hypochlorite. Monitored parameters: pressure, temperature, flow rate, SDI.
REVERSE OSMOSIS
In reverse osmosis water moves from an area of low water concentration to a region of high
water concentration under a pressure gradient across a semi permeable membrane. All other
molecules except water are retained on the side of lower water concentration. RO membrane is
62. 0.01micron pore size and is sensitive to temperature and chlorine. It is made of polyamide. RO is
in series to-ensure efficiency of the RO process in addition to minimizing wastage.
ELECTRODE –IONISATION (EDI)
Electrode ionization uses an electric field to remove ions and polar species from an aqueous
stream. EDI is used with reverse osmosis to replace ion exchange resin-mixed beds, which
require onsite or offsite chemical regeneration.
By eliminating resin regenerating chemicals, EDI delivers significant economic and
environmental benefits. In addition, EDI’s continuous process improves water quality by
reducing spikes and upsets.
Monitored parameters: pressure, conductivity, temperature, voltage
STORAGE AND DISTRIBUTION
The storage and distribution unit consists of a 2000 liter tank, and S&D pump, a U.V unit and a
recirculating pipe line.
U.V unit consists of a U.V lamp that is enclosed in a transparent quartz sleeve. As water passes
through the flow chamber the microbes are exposed to the U.V rays which damage their DNA
structure hence preventing their reproduction and multiplication. Increased intensity of rays
increase the kill of the microorganisms.
Monitored parameters include UV Intensity, temperature, conductivity, flow rate.
63. 7 LESSONS LEARNT
The time I spent at CIPLAQCIL I learnt a lot .these include
The knowledge about the process of the manufacture of medicines.
All manufacturing facilities follow current good manufacturing practices(cGMPs)
The uses of a chemical engineer in a pharmaceutical
The need for controlled environment in a facility
Team work .I improved on my networking skills .for instance I was challenged to seeing
faces I had never and had to make friends so that the training would go on smoothly.
8 CHALLENGES
Identifying places for industrial training was difficult since some institutes were not in
need of trainees.
The university does not define the characteristics of places for industrial training. This
would lead to trainees diverting to other fields.
Operation of Some equipment at the factory required more training. This limited our
practical activity in the field.
Some departments were allocated less time so it was a challenge learn everything.
Some information at the factory was limited to only specified personnel making quest for
information hard.
9 CONCLUSIONS
The training was highly motivating. Usage of SOPs, cGLPs, cGMPs was highly emphasized.
Most of the objectives in the industry were achieved but some of them couldn’t be achieved due
to the time allocated to us by the industry. I have learned how science and engineering can
interact in useful ways and how remarkable research can occur even when it is ‘profit driven’; at
CiplaQCIL creativity is not limited and true innovation occurs. The company gave me to chance
to study the loss of primary packaging material on Lumartem 24s blister packing.
I was lucky enough to work with a group of enthusiastic and communicative people, who were
passionate about what they are doing in the industry.
64. The atmosphere at CiplaQCIL is unique and hope that it stays that way. It has been a unique
opportunity and one that I will not soon forget. My time there has been eye opening especially in
the departments of Engineering, Quality Control and Production. I thoroughly recommend the
experience to any other student who is thinking of applying. Despite the success achieved there
are a few challenges which I hope can be addressed progressively given more opportunity?
10 RECOMMENDATIONS
The university should identify potential areas for placement in order to avoid students
going to place where their course does not fit.
The university should improve the industrial training policy by my making agreements
with certain industries and agreeing on the number of students to be sent to the industries.
The industry should identify the period needed for certain departments instead of giving
them equal time.
Capacity building for handling complex equipment and this required another chance for
placement to be negotiated by the university
11 REFERENCES
David J. am Ende, 2011, CHEMICAL ENGINEERING IN THE PHARMACEUTICAL
INDUSTRY John Wiley & Sons, Inc.
http://www.ciplaqcil.co.ug
USP 36-Nf 31 2013 (3 Vol Set) (U.S. Pharmacopoeia: National Formulary)
British Pharmacopoeia 2014978-9380501246
2014/2015 Uganda National Development Plan National development Plan
Good manufacturing practices for pharmaceutical products. In: WHO Expert Committee
on Specifications for Pharmaceutical Preparations. Thirty-seventh report. Geneva, World
Health Organization, 2003 (WHO Technical Report Series, No. 908), Annex 4.
CiplaQCIL 2014 Komboa newsletter volume 10