This document provides an overview of validation requirements in the pharmaceutical industry. It begins with definitions of validation from FDA guidelines in 1987 and 2011. Validation originated in the 1970s focused on sterilization, and has now expanded to all product, process, and facility matters. Validation is required to assure quality, is a regulatory requirement, and reduces costs. The stages of validation for a product and process are outlined, including process design, process qualification, and continuous process verification. Key aspects of validation like process validation, change control, and documentation are also summarized.
Introduction to Pharmaceutical Validation, Scope & Merits of Validation, Validation and calibration of Master plan, Hrs ICH & WHO guidelines for calibration and validation of
equipment's, Validation of specific dosage form, Types of validation. Government regulation, Manufacturing Process Model, URS, DQ, IQ, OQ & P.Q. of facilities.
Introduction to Pharmaceutical Validation, Scope & Merits of Validation, Validation and calibration of Master plan, Hrs ICH & WHO guidelines for calibration and validation of
equipment's, Validation of specific dosage form, Types of validation. Government regulation, Manufacturing Process Model, URS, DQ, IQ, OQ & P.Q. of facilities.
U.S.F.D.A. was the pioneer in the concept of process validation.
Validation had proven to be an important tool for quality management of pharmaceutical according to ISO 9000:2000.
Process validation is a requirement of the current Good Manufacturing Practices (cGMP) Regulations for Finished Pharmaceuticals. Validation is defined as a documented program that provides a high degree of assurance that a specific process, method, or system will consistently produce a result meeting pre-determined acceptance criteria.
Process validation incorporates a lifecycle approach linking product and process development, validation of the commercial manufacturing process and maintenance of the process in a state of control during routine commercial production.
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U.S.F.D.A. was the pioneer in the concept of process validation.
Validation had proven to be an important tool for quality management of pharmaceutical according to ISO 9000:2000.
Process validation is a requirement of the current Good Manufacturing Practices (cGMP) Regulations for Finished Pharmaceuticals. Validation is defined as a documented program that provides a high degree of assurance that a specific process, method, or system will consistently produce a result meeting pre-determined acceptance criteria.
Process validation incorporates a lifecycle approach linking product and process development, validation of the commercial manufacturing process and maintenance of the process in a state of control during routine commercial production.
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validation is a technique of validating the final product either starting from the raw material or within the process, its all types cover the methods of validation and sequence in the product development.
Validation.
Validation is establishing documented evidence which provides a high degree of assurances that a specific process or equipment will consistently produce a product or result meeting its predetermined specifications and quality attributes”.
A system must be qualified to operate in a validated process
The results of analytical procedures should be:
— reliable
— accurate
— reproducible
The characteristics that should be considered during validation of analytical methods are:
— specificity
— linearity
— range
— accuracy
— precision
— detection limit
— quantitation limit
— robustness
Qualification and Validation have big Weightage in the Regulatory Compliance and GMP. Qualification and Validation only can guarantee about the Product Safety, Integrity, Strength, Purity and Quality assurance.
Introduction, Regulatory requirements for validation, Role of FDA, Code of Federal regulation, Validation life cycle, Significance of validation, Types of validation, Process valiadation, Phases of process validation, Process capability design, Process Qualification, Validation maintainance phase
Types of Process validation, Examples
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Sustainability has become an increasingly critical topic as the world recognizes the need to protect our planet and its resources for future generations. Sustainability means meeting our current needs without compromising the ability of future generations to meet theirs. It involves long-term planning and consideration of the consequences of our actions. The goal is to create strategies that ensure the long-term viability of People, Planet, and Profit.
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1. Introduction and Key Concepts of Sustainability
2. Principles and Practices of Sustainability
3. Measures and Reporting in Sustainability
4. Sustainability Implementation & Best Practices
To download the complete presentation, visit: https://www.oeconsulting.com.sg/training-presentations
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1. Overview of Validation Requirements
in
Pharmaceutical Industry
Kaushik Desai
Chairman,
Industrial Pharmacy Division
Indian Pharmaceutical Association
www.ipapharma.org
1
3. “ Establishing the documented evidence which
provides a high degree of assurance that a
specific process will consistently produce a
product of predetermined specifications and
quality attributes.”
(FDA Guidelines 1987)
3
4. “Process validation is defined as the collection
& evaluation of data, from the process design
stage through commercial production, which
establishes scientific evidence that process is
capable of consistently delivering quality
product.”
(FDA Guidelines, 2011)
4
5. “Action of proving, in accordance with the
principles of Good Manufacturing Practice
(GMP), that any procedure, process,
equipment, material, activity or system
actually leads to expected results.”
(EU GMP 1997)
5
12. User Requirement Specification (URS)
A description of the requirements of the facility
(project) in terms of product to be manufactured,
required throughput and conditions in which the
product should be manufactured.
Approved statements prepared by the user which
defines what is required by the project.
12
13. Design Qualification (DQ)
Documented review of the design, at an
appropriate stage in a project, for conformance
to operational and regulatory expectations.
(Note : Not an obligation)
13
14. Impact Assessment
The process of evaluating the impact of the
operating, controlling, alarming and failure
conditions of a system on the quality of a
product
14
15. Factory Acceptance Testing (FAT)
Inspection and static and/or dynamic testing of
systems or major system components to
support the qualification of an equipment
system conducted and documented at a
supplier site.
(Note : Not an obligation)
15
16.
Documented verification that all aspects of a facility,
utility or equipment that can affect the product
quality adhere to approved specifications and are
correctly installed.
The process of checking/verifying the installation to
ensure that the critical components meet the
approved specifications and that they are installed
correctly in accordance with design documentation.
16
17.
To establish that the critical components are installed
correctly
and
in
accordance
with
design
documentation requirements (i.e. PO’s, Contracts
etc.), that supporting documentation is in place and of
suitable quality.
To record the checks and verifications for critical
components in Direct Impact Systems.
17
19.
Instrument/Control Devices Verification
Equipment Verification
Piping Installation Verification
Discrepancy/Justification and corrective Action
As built P&I Diagrams
Specifications
Conclusions
References
Modification/ Change Control
Attachments / Appendices
19
20. Parameters
Does the vessel meet the design specification?
Does the agitator assembly meet the design specification?
Is the motor housing earthed?
Is the motor over current device set to correct setting?
Is all the pipe work connected?
Are all instruments installed as per P&I diagram?
Have all the temperature indicators been calibrated?
Is calibration procedure available?
Are operation and maintenance manuals available?
all electrical connections securely and safely fitted?
Is insulation complete?
Is vessel clean and free from dirt?
20
21.
After protocol execution is complete and
deviations evaluated, post execution approval
is required.
Requires sign off by original signatories.
IQ execution should be complete and approved
prior to the start of OQ.
21
22.
Calibration
Demonstrating that a measuring device
produces results within the specified limits of
those produced by a reference standard over
an appropriate range of measurements.
The devices are normally tagged and
supported by a maintenance procedures.
22
23. Site Acceptance Testing (SAT)
Inspection and dynamic testing of systems or
major system components to support the
qualification of an equipment system
conducted at a client site.
(Note : Not an obligation)
23
24.
Documented verification that all aspects of
a facility, utility or equipment that can affect
product quality operate as intended
throughout all anticipated ranges. It is the
process of testing to ensure that individual
components and systems operate as
specified, and how that information is
recorded.
24
25.
To establish through documented testing, that all
critical components and direct impact systems are
capable of operating within established limits and
tolerances.
To test parameters that regulate the process or
product quality. To verify the proper operation of
controllers, indicators, recorders, alarms and
interlocks, is performed and documented during the
operational qualification testing.
25
27.
Sequence testing
Test data sheets
SOP’s
Conclusions
Modification / change control
Discrepancy/Justification and corrective action
Operational Qualification Summary
References
Attachments/Appendices
- Verification of test instruments
- Chart recordings
- P&I diagrams
- Printouts
27
28. Parameters
Have all Installation Qualification been completed for this system?
Is the system clean and free from dirt?
Is the direction of the rotation of agitator correct?
Check the operation of the agitator emergency stop?
Check the operation of all agitator controls, both on the main and local
panels?
Check that the agitator in the vessel free to turn?
Pressurize the vessel and record the pressure drop for 10 min.
Perform a vacuum test and record the vacuum drop.
28
29.
Documented verification that all aspects of
a facility, utility or equipment that can
affect the product quality perform as
intended in meeting the predetermined
acceptance criteria.
29
30.
To integrate procedures, personnel, systems
and materials to verify that the utility /
environment / equipment / support systems
produces the required output. This output
may be a product contact utility, sterilization
condition or environment.
30
32. Process Validation
The documented verification providing a high
degree of assurance that a specific process will
consistently produce a product meeting its
predetermined specifications and quality
attributes.
The new guidelines aligns process validation
activities with a product life cycle concept.
32
34. Life Cycle of the product & the process
Stage 1 – Process Design
Stage 2 – Process qualification
Stage 3 - Continuous process verification
34
35.
It is the activity of defining the commercial manufacturing
process that will be reflected in planned master production
and control records.
The goal of this stage is to design a process suitable for
routine commercial manufacturing that can consistently
deliver a product that meets its quality attributes.
It is based on the knowledge gained through development &
scale-up activities.
35
36.
During this stage, the process design is evaluated to
determine if the process is capable of reproducible
commercial
manufacturing.
The
products
manufactured during this stage, if acceptable , can be
released for distribution.
Two Aspects
Design of facility and qualification of equipment and
utilities.
Process Performance Qualification ( PPQ).
36
37. Def.: “Releasing for distribution a lot of finished
product, manufactured following a qualification
protocol, that meets the standards established in
the protocol, but before the entire study has been
executed”.
Orphan Drugs
Specific drug for specific use
Shor t Shelf-life radio pharmaceuticals
37
38.
The goal of this stage is continual assurance that the
process remains in a state of control ( the validated state)
during commercial manufacture.
The cGMP requirements, specifically the collection &
evaluation of information & data about the performance
of the process will allow detection of undesired process
variability.
This stage is also applicable for legacy products.
38
39. Change Control
Formal evaluation of the potential impact of
planned modifications on the validated status
of a product, process or facility.
39
40.
Training personnel for IQ/OQ execution.
The purpose of the equipment/ system.
Use of test equipment
Applicable SOP’s
cGMP documentation of training
Document all training
Periodically review training requirements
40
41.
A document that summarizes and analyses
the test results at the end of PQ.
Provides a conclusion about the ability of the
system to consistently meet acceptance
criteria.
May be a stand alone document at each
stage of IQ/OQ and PQ to summarize results.
41
42. Commissioning and Qualification
Project Phases
Technology Transfer
Conceptual Design
Basic Design
Detailed Design
Procurement
Construction
Pre commissioning
Commissioning
Validation Phases
Collecting data
Preliminary VMP
Detailed VMP
Detailed planning,DQ
IQ
OQ
Process operation / Validation
42
44. The company’s overall policy, intentions and
approach to validation, including :
Validation of production processes
Cleaning procedures
Analytical methods
In-process control test procedures
Computerized systems
Persons responsible for design, review, approval
Documentation of each validation phase
44
45.
Product validation is NOT ……
- just 3 batches that meet specifications
Product validation is ……
- an ongoing process to build confidence into
the manufacturing activities
- an ability to demonstrate consistency at any
time.
45
46.
Cleaning validation is establishing
documented evidence that the equipment
is consistently cleaned from product,
microbial and cleaning agent residues to
predetermined acceptable levels.
46
47. A written procedure for cleaning validation
which includes :
Responsibility for development, performance and
approval of the validation study.
Establishment of SOP’s
Acceptance criteria
- defined to prevent cross contamination
- definition of residue limits
47
48.
Cleaning procedure for each piece of equipment
- Flow charts and diagrams
- Cleaning agents, concentration, volume
- Frequency
- time left ‘dirty’
48
50.
Validation report
- Results Vs. acceptance criteria
- Deviations and how handled
- Conclusion that cleaning process is
validated
50
51.
Major change in cleaning procedure
Change in cleaning agent
New equipment
51
52.
Knowledge of the materials
- Potency of the drug
- Pharmacological and toxic properties
- Degradation products
- Cleaning agents
- Micro residues
52
53. Residual Limits must be………….
Practical
Achievable
Verifiable
Safe
FDA does not set acceptance specifications
(limits).
53
54. MAC = TD x BS x SF / LDD
MAC = Maximum Allowable Carryover
TD = Single Therapeutic Dose
BS = Batch size of next product to be
manufactured on the same equipment.
SF = Safety Factor
LDD = Largest Daily Dose of the next product
in the same equipment.
54
55. Ranitidine Tablets - Ibuprofen Tablets
TD = Single Therapeutic Dose = 150 mg Ranitidine-Tab
BS = Batch Size = 100 kg of Ibuprofen
SF
= Safety Factor = 1/1000
LDD
= Largest Daily Dose of the next product in the same
equipment = 200 mg X 5 tablets of Ibuprofen
MAC
= Max Allowable Carryover = 150 X 100 X 1000 x
1000 X 1/1000 X 1/1000
i.e 15000 mg in 100 kg Batch size
i.e 150 mg in 1 kg = 150 ppm
55