Sop Cleaning Rev 06 - 2018 Rev Baru (Repaired)
Sop Cleaning Rev 06 - 2018 Rev Baru (Repaired)
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PT. CAPRIFARMINDO STANDARD OPERATING PROCEDURE
LABORATORIES Revision No.: 06
Subject : Production Equipment Document No.: Next Review Date:
Cleaning Validation VAL-LV/SOP/CP/001
Location/Department : Validation
Effective Date : Prepared by, Reviewed by, Reviewed by,
Solid Production
Validation Engineer Validation Manager Manager I
Reviewed by, Reviewed by, Reviewed by,
TABLE OF CONTENT
1. PURPOSE.....................................................................................................................................3
2. SCOPE..........................................................................................................................................3
3. DEFINITION...............................................................................................................................3
3.1. Acceptance Criteria.............................................................................................................3
3.2. Bracketing...........................................................................................................................3
3.3. Change Management...........................................................................................................3
Solid Production
Validation Engineer Validation Manager Manager I
Reviewed by, Reviewed by, Reviewed by,
11. REVALIDATION..................................................................................................................... 16
..
1. PURPOSE
This procedure describes guidelines to perform cleaning validation as authentication of
assurance that after performed cleaning process of production machine would not happened
contamination between products that contact with machine before and after cleaning process.
2. SCOPE
This procedure prevail to cleaning validation of all production machine where it is possibility
happen contamination that is used in PT. Caprifarmindo Laboratories. Validation of cleaning
procedures on required for all equipment, surfaces, and other areas that may have a direct
impact on product quality. To validated all cleaning activities is a difficult undertaking and the
plan requires a matrix to be developed to identity products, equipment, cleaning procedures so
that worst case condition can be selected as a priority for cleaning validation.
It is generally considered that the cleaning activities within a pharmaceutical manufacturing
facility are on going and require a program for verification of the reliability of the procedures.
To reconfirm validated status, some subset of validation must be repeated as specified
intervals, either in the form of an audit or other periodic monitoring.
The most common cleaning procedures to be validated are :
2.1 Cleaning of processing vessels, tanks and transfering equipment.
2.2 Cleaning of filling, compressing, coating, and stripping machine.
2.3 Cleaning of sampling equipment and weighing tools.
3. DEFINITION
3.1 Acceptance Criteria
Specific criteria for results of either process monitoring or a test. Criteria are defined
in a validation or qualification protocol and must be met in order for the process to be
considered validated or the equipment to be qualified.
3.2 Bracketing
Grouping of products base on its water solubility, minimal therapeutic dose, formula
complexity, and concentration by concern about toxicity, characteristic, and adverse
reaction of active ingredient, production frequency, batch size.
3.3 Change Management
A formal system by which qualified representatives of appropriate disciplines review
proposed or actual changes that might affect the validated status of facilities, systems,
equipment or processes. The intent is to determine the need for action that would
ensure and document that the system is maintained in a validated state.
3.4 Cleaning Validation
Cleaning validation is documented evidence that an approved cleaning procedure will
provide equipment which is suitable for processing medicinal products.
3.5 Cross Contamination
Contamination of a starting material or of a product with another material or product
3.6 Final Rinse
The last rinse of a piece of equipment during the cleaning procedure.
3.7 LD50
Lethal Dose 50 in g/kg animal. The identification of the animal (mouse rat etc.) and
the way of entry (IV, oral etc.) is important.
3.8 Re-Validation
A repeat of the process validation to provide an assurance that changes in the
process/equipment introduced in accordance with change control procedures do not
adversely affect process characteristics and product quality.
3.9 Recovery Study
A laboratory study combining the sampling method and analytical to determine the
quantitative recovery of a specific residue for a defined surface.
3.10Risk Analysis
Method to assess and characterize the critical parameters in the functionality of an
equipment or process.
3.11Risk Management
The systematic application of quality management policies, procedures, and practice
to the tasks of assesing, contolling, comunicating and reviewing risk.
3.12Worst Case
A condition or set of conditions encompassing upper and lower processing limits and
circumstances, within standard operating procedures, which pose the greatest chance
of product or process failure when compared to ideal conditions. Such conditions do
not necessarily induce product or process failure.
4. REFERENCES
4.1 National Agency of Drugs and Food Administration of Republic of Indonesia. (2012).
Good Manufacturing Practice: Point 12, Qualification and validaion.
4.2 National Agency of Drugs and Food Administration of Republic of Indonesia. (2012).
Guideline on Good Manufacturing Practice: Point 12, Qualification and validaion.
4.3 PIC/S [Pharmaceutical Inspection Convention Pharmaceutical inspection Co-Operation
Scheme]. (2017). Guide to Good Manufacturing Practice for Medical Products. Document
PE 009-13 (Annexes).
4.4 APIC [Active Pharmaceutical Ingredients Commitee], (2016). Guidelines on Aspect of
Cleaning Validation in Active Pharmaceutical Ingredient Plants.
4.5 WHO [Word Health Organization]. (2006). Annex 4 : Supplementary Guidelines on Good
Manufacturing Practices: Validation-Appendix 3: Cleaning Validation TRS No. 937.
4.6 PDA [Parenteral Drug Association]. (2012). Points to Consider for Cleaning Validation.
Thecnical Report No.29.
4.7 PIC/S [Pharmaceutical Inspection Convention Pharmaceutical inspection Co-Operation
Scheme]. (2007) Recommendation on Validation Master Plant, Installation and
Operational Qualification, Non-Sterile Process Validation, Cleaning Validation.
Document PI 006-3.
5.2.3 Validating the analytical method used to analyze traces of active ingredient and
analyze microbial contaminant.
5.2.4 Testing samples according to validated analytical method.
5.2.5 Conducting investigation with production, validation and QA if there is any out
of specification case.
5.3 Validation Department
Responsible for:
5.3.1 Preparing an appropriate approval of validation protocol and validation
report.
5.3.2 Coordinating activities to conduct an affective and reliable cleaning
validation.
5.3.3 Supervising the operation to ensure that everything is done according to this
protocol.
5.3.4 Conducting investigation with production, QC and QA if there is any out of
specification case.
5.4 QA Department
Responsible for:
5.4.1 Approving the protocol and report of cleaning validation.
5.4.2 Ensuring that validation activities conforms with quality assurance
requirements.
5.4.3 Conducting investigation with production, QC and QA if there is any out of
specification case.
6.4 After the validation protocol has reviewed and approved by related person, do
coordination with related department.
6.5 Perform the cleaning validation execution by refer protocol validation already been
made.
6.6 Perform 3 consecutive batches cleaning validation in the production process facility
purpose.
6.7 Record and documentation the result of execution cleaning validation into cleaning
validation report (cleaning validation report will be refer to SOP No. VAL-
NS/SOP/CP/002 : Qualification and Validation Standart Document).
6.8 Bracketing of cleaning validation perform for every new product transferred from RnD
to plant or every once a year.
6.9 Revalidation of cleaning validation perform if any change in bracketing of cleaning
result and if any change in cleaning procedures.
6.10 Perform the recovery test execution by refer to protocol recovery test already been
made.
6.11 Record and documentation the result of recovery test into recovery test report (recovery
test report will be refer to SOP No. VAL-NS/SOP/CP/002 : Qualification and Validation
Standart Document).
7. EQUIPMENT
All equipments that is needed during validation are :
7.1 Stainless Steel Frame 5x5 cm
7.2 Cotton Swab
7.3 Reaction tube
7.4 Sampling Bottle/Vial 10 mL and 100 mL
8. PROCEDURES
8.1 Bracketing
The cleaning processes of multiple product use equipment in manufacturing facilities are
subject to requirements for cleaning validation. The validation effort could be huge. In
order to minimize the amount of validation required, a worst case approach for the
validation can be used.
The objective of a bracketing project is for the company to demonstrate that it has a
scientific rationale for its worst case rating of the substances in the cleaning validation
program. The first thing to do is to make groups (“bracketing”) from which worst cases
will later be selected based on the results from the rating. Bracketing procedure will be
performed based on the following procedure:
8.1.1 Collect the solubility in water of each substance in formulation of products using
the specified machine.
8.1.2 Collect the LD50 of each active ingredients in formulation of products using the
specified machine.
8.1.3 Collect the Minimum Therapeutic Dose of each active ingredients in formulation
of products using the specified machine.
8.1.4 Collect the concentration of each active ingredient in formulation of products
using the specified machine.
8.1.5 Give score to each product based on its drug category, solubility, toxicity,
minimum therapeutic dose, concentration of active ingredient, formulation
complexity, batch size, and production frequency.
8.1.6 Choose the worst case product based on the most high score substance from
procedure.
There are two methods of sampling that are considered to be acceptable, direct surface
sampling (swab method) and indirect sampling (use of rinse solutions).
8.2.1 Determining Active Ingredient Residue
1. Swab Method
For determining active ingredients residue using swab method, the samples are
taken according to the following steps:
a. Use gloves to minimize contamination to the cotton swab,
and surfaces which will be swabbed.
b. Pre-treat the swab in the sample solvent (i.e. purified water)
by saturate the swab with solvent in the test tube.
c. Squeeze the swab in to the wall of test tube twice. Do not let
the swab too sweat.
f. Swab the cotton swab into the media in petri disc. Close the petri
disc, label with sample position, date, etc
g. Send the samples to the QC.
2. Rinse Method
For determining microbial contaminant, the samples are taken according to
the following procedure:
a. Rinse the cleaned equipment with Purified water.
b. Collect approximately 2 x 100 mL from the final rinse into a clean and
sterile glass bottle with lid, and label.
c. Send the samples to QC.
The other criterions must be calculated, evaluated and selected to ensure that any
carry-over product residue meets the all criterion (select the strictest acceptance
criteria):
1. Visual Inspection
The acceptance criteria for visual inspection is a mandatory and shall
always be applied.
Acceptance criteria:
“No quantity of any residue will be visible on the equipment after
cleaning procedures are performed and on the sampling swab after
swabbing sampling are performed”.
2. Chemical Residue
Choose the most stringent criterion from dose criterion, surface criterion,
and 10 ppm criterion as acceptance criteria. The recovery test for swab
method is should be greater than 80 %.
a. Dose Criterion
Not more than 0.001 dose of product residue will be appear in the
maximum daily dose of another product.
Equation:
b. Surface Criterion
Equation:
MTD P SF A Swab
MAR P 2
___ (mg/cm2 area swabbed
1 cm
c. 10 ppm Criterion
Not more than 10 ppm of product residue will appear in another
product.
Equation:
R MBSf A Swab
MAR P ___(mg/cm 2 area swabbed )
A tot
d. Microbiology Limit
Not more than 50 CFU / 25 cm2 area swabbed.
1. Visual Inspection
The acceptance criteria for visual inspection is a mandatory and shall
always be applied.
Acceptance criteria:
“No quantity of residue will be visible on the equipment after cleaning
procedures are performed and in the last rinsing solution which taken as
sample”.
2. Chemical Residue
Choose the most stringent criterion from dose criterion, surface criterion,
and 10 ppm criterion as acceptance criteria.
a. Dose Criterion
Not more than 0.001 dose of any product will be appear in the
maximum daily dose of another product.
Equation:
b. Surface Criterion
Equation:
MTD P SF A Rinse
MAR P ___ (mg/mL sample volume)
1 cm 2 VRinse
c. 10 ppm Criterion
Not more than 10 ppm of product residue will appear in another
product.
Equation:
R MBSf A Rinse
MAR P ___(mg/mL sample volume)
A tot VRinse
d. Microbiology Limit
Rinse water microbiological analysis result must be under 100
CFU/ml (volume of rinse sample).
8.4.2 Take the samples at the critical point as described at point “a” (above) according to
the chosen sampling method (point 8.2)
4. pH and Conductivity
5. ELISA and Electrophoresis
8.7.2 For manual cleaning, parameters that may be monitored include visual examination
during manual cleaning, times, temperatures, cleaning agent concentration,
operators ability (training programme).
9. EVALUATION
9.1 Enclosed all data and graphics during cleaning validation execution.
9.2 Analysis data during cleaning validation execution.
9.3 Compare actual data and acceptence criteria.
11. REVALIDATION
Revalidation should be considered under the following circumstances:
Change of:
11.1 Cleaning method
11.2 Cleaning agent
11.3 Cleaning procedures
11.4 Product (bracketing/grouping)
11.5 Process equipment
Cleaning validation will be conducted for 3 consecutive batches. Specifically the scope of the
plan applies to cleaning validation of processing equipment.
13. DOCUMENTATION
All the observation result is documented into cleaning validation report.
Cleaning validation report, covers:
13.1 Sampling Plan.
13.2 Determination of Acceptance Criteria.
13.3 Cleaning Validation Execution Results Form.
13.4 SOP of Cleaning Related.
15. ATTACHMENT
15.1 Form monitoring of Recommendation Cleaning Validation (VAL-LV/FOR/CP/006).
Revision
Date Description Originator
No
Revision
Date Description Originator
No
Added point 7. Equipment
Added point 9. Evaluation
Added point 10. Deviation Report
Added point 12. Cleaning Validation
Recommendation.
Added point 13. Documentation
Added point 15. Attachment