seminar on aseptic processing operation by ranjith kumar kankala . m.pharm (i sem )
DESCRIPTION
Seminar on Aseptic Processing operation by Ranjith Kumar kankala . M.Pharm (I sem ) Department of Pharmaceutics BLUE BIRDS COLLEGE OF PHARMACY Affiliated to Kakatiya university Warangal 2009. Schedule (contents) . Introduction to aseptic processing, - PowerPoint PPT PresentationTRANSCRIPT
Seminar onAseptic Processing operation
byRanjith Kumar kankala
MPharm (I sem)
Department of PharmaceuticsBLUE BIRDS COLLEGE OF PHARMACY
Affiliated to Kakatiya universityWarangal
2009
Schedule (contents) Introduction to aseptic processing Aseptic Processing vs Terminal Sterilization contamination
Sources and control Microbial environmental monitoring Microbiological testing of air and water Characterization of aseptic process Media and incubation conditions Conclusion References
Aseptic Processing
Aseptic Processing is the processing of drug components ( drug product containers excipients etc) in a manner that makes impossible of microbiological contamination of the final sealed product
Progression of Symptoms
FeverDecreased Blood PressureRapid Breathing and Heart RateSkin LesionsSpontaneous Blood Clotting Organ FailureDeath
ldquoSepsis is a serious medical condition characterized by a whole-body inflammatory state caused by infectionrdquo
Causes of sepsis
Sterile drug manufacturers should have a keen awareness of the public health implications of distributing a non-sterile product Poor cGMP conditions at a manufacturing facility can ultimately pose a life-threatening health risk to a patientrdquo
Asepsis is the practice to reduce or eliminate contaminants (such as bacteria viruses fungi and parasites) from entering the field to prevent infection Ideally a field is sterile mdash free of contaminants mdash a situation that is difficult to attain However the goal is elimination of infection
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Schedule (contents) Introduction to aseptic processing Aseptic Processing vs Terminal Sterilization contamination
Sources and control Microbial environmental monitoring Microbiological testing of air and water Characterization of aseptic process Media and incubation conditions Conclusion References
Aseptic Processing
Aseptic Processing is the processing of drug components ( drug product containers excipients etc) in a manner that makes impossible of microbiological contamination of the final sealed product
Progression of Symptoms
FeverDecreased Blood PressureRapid Breathing and Heart RateSkin LesionsSpontaneous Blood Clotting Organ FailureDeath
ldquoSepsis is a serious medical condition characterized by a whole-body inflammatory state caused by infectionrdquo
Causes of sepsis
Sterile drug manufacturers should have a keen awareness of the public health implications of distributing a non-sterile product Poor cGMP conditions at a manufacturing facility can ultimately pose a life-threatening health risk to a patientrdquo
Asepsis is the practice to reduce or eliminate contaminants (such as bacteria viruses fungi and parasites) from entering the field to prevent infection Ideally a field is sterile mdash free of contaminants mdash a situation that is difficult to attain However the goal is elimination of infection
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Aseptic Processing
Aseptic Processing is the processing of drug components ( drug product containers excipients etc) in a manner that makes impossible of microbiological contamination of the final sealed product
Progression of Symptoms
FeverDecreased Blood PressureRapid Breathing and Heart RateSkin LesionsSpontaneous Blood Clotting Organ FailureDeath
ldquoSepsis is a serious medical condition characterized by a whole-body inflammatory state caused by infectionrdquo
Causes of sepsis
Sterile drug manufacturers should have a keen awareness of the public health implications of distributing a non-sterile product Poor cGMP conditions at a manufacturing facility can ultimately pose a life-threatening health risk to a patientrdquo
Asepsis is the practice to reduce or eliminate contaminants (such as bacteria viruses fungi and parasites) from entering the field to prevent infection Ideally a field is sterile mdash free of contaminants mdash a situation that is difficult to attain However the goal is elimination of infection
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Progression of Symptoms
FeverDecreased Blood PressureRapid Breathing and Heart RateSkin LesionsSpontaneous Blood Clotting Organ FailureDeath
ldquoSepsis is a serious medical condition characterized by a whole-body inflammatory state caused by infectionrdquo
Causes of sepsis
Sterile drug manufacturers should have a keen awareness of the public health implications of distributing a non-sterile product Poor cGMP conditions at a manufacturing facility can ultimately pose a life-threatening health risk to a patientrdquo
Asepsis is the practice to reduce or eliminate contaminants (such as bacteria viruses fungi and parasites) from entering the field to prevent infection Ideally a field is sterile mdash free of contaminants mdash a situation that is difficult to attain However the goal is elimination of infection
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Causes of sepsis
Sterile drug manufacturers should have a keen awareness of the public health implications of distributing a non-sterile product Poor cGMP conditions at a manufacturing facility can ultimately pose a life-threatening health risk to a patientrdquo
Asepsis is the practice to reduce or eliminate contaminants (such as bacteria viruses fungi and parasites) from entering the field to prevent infection Ideally a field is sterile mdash free of contaminants mdash a situation that is difficult to attain However the goal is elimination of infection
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Asepsis is the practice to reduce or eliminate contaminants (such as bacteria viruses fungi and parasites) from entering the field to prevent infection Ideally a field is sterile mdash free of contaminants mdash a situation that is difficult to attain However the goal is elimination of infection
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Producing drug products by
Terminal sterilization Product containers are filled and
sealed under high-quality environmental conditions designed to minimize contamination but not to guarantee sterility
Product in its final container is subject to a sterilization process such as heat or irradiation
Aseptic processing
Drug product container and closure are subject to sterilization separately and then brought together
Because there is no process to sterilize the product in its final container it is critical that containers be filled and sealed in an extremely high ndashquality environment
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Terminal Sterilization
Drug Product
Container Closure
Excipiants
Sterilization Process
Sterile Drug
Product
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Aseptic Processing Drug
Product
Sterilization Process
Container
Closure
Excipient
Sterilization Process
Sterilization Process
Sterilization Process
Sterile Closure
Sterile Excipient
Aseptic Processin
g
Sterile Drug
Product
SterileContainer
Sterile Final
Product
Can use multiple sterilization processes each optimized for the individual component
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Bacteria virus fungi and other viable microbes cause a serious contamination
Bacterial spores and endotoxins Non viable Particles like dust fibers or other material are
suspended in the air and may contaminate product
Contaminating agents
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Humans and bacteria
Over 200 different species of bacteria are found associated with humans
Bacteria are found in the intestines eyes nares mouth hair and skin
Dry skin can have 1000rsquos of microbes mm2
Staphylococcus epidermidis Scanning EM CDC
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Sources of Contamination
Personnel born contaminants Poor or improper Sanitization Procedures deficient or poorly
executed Air born contaminants Inadequate HEPA seal (over 90 vials contaminated) Velocity through HEPA Filters Variable velocities between
filters Inadequate laminar flow resulted Low or undetectable velocity at work surface
Mechanical failure of filling tank main pump failure cooling system leaks at joints
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Control
1st step ndash eliminating the source of
contamination 2nd Step - Reduce the Risk of
contamination through Sterile barriersSurface monitoring Aseptic technique
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Gowning (sterile barrier)
If people are a major source of contamination we avoid contaminating the product while we process it
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Surface Monitoring
Touch or Contact plates - RODAC
Plates (Replicate Organism Detectionand Counting)
Swabs
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Aseptic Technique (skill)
Contact sterile materials only with sterile instruments Operators should not contact sterile products containers
closures or critical surfaces with any part of their gown or gloves
Keep the entire body out of the path of unidirectional airflow Approach a necessary manipulation in a manner that does not
compromise sterility of the product
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Whatrsquos wrong with this picture
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
CORRECT
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Horizontal airflow Vertical airflowwwworsodnihgovdspubsbscgraphicsfig3gif
Unidirectional airflow
The operator should never come between the
air source and the product
pressure differential bn critical area from external environment (175-50 Pa)
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Disinfectants
ISOPROPYL ALCOHOL (70) Powerful disinfectant Effectively kills bacteria and fungi
Mode of action denatures proteins dissolves lipids and can lead to cell membrane disintegration
But does not inactivate spores eg phenols Alcohols Aldehydes etc
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Sporicidal agents Glutaraldehyde Formaldehyde sodium hypochlorite Iodine and iodophors Peroxygens Ethylene oxide P- Propiolactone
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Isolators Advantage
No direct contact between operator amp product
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Microbial identification should extend to the species level
Routine traditional techniques phenotypic and
biochemical Genotypic techniques are
suggested for failure investigations
Microbial Environmental Monitoring Identification
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Phenotypic technique
Gram Stain
Identifying Microbes
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Staphylococcus xylosus
Reduction of Tetrazolium Violet
Biochemical Assays
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Genotypic Methods
Use DNA sequence (often ribosomal RNA genes rDNA) to identify organism
Faster and more accurate then traditional biochemical and phenotypic techniques
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
QC Micro Identifying Microbes Genotype Based AssayPCR Polymerase Chain Reaction
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Extremely heat stable ndash recommended conditions for inactivation are 180 0 C for 3 hours
Endotoxin a pyrogenic (fever inducing) substance (eg lipopolysaccharide) present in the bacterial cell wall Endotoxin reactions range from fever to death
Endotoxin Testing
LAL Assay (Limulus amoebocyte lysate)ENDOTOXIN LIMIT FOR WFI IS 025 EUml
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Microbiological testing of water Universal solvent Used as Vehicle and used to rince and cleaning of
apparatus Water should also be tested for presence of coliforms andor
pseudomonads if appropriate (may cause biofilm) Water should be tested using R2A agar (low nutrient for the recovery
of water borne organisms) incubated for at least 5 days at 30-35degC Sampling procedures should follow those used in production
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Microbiological testing of airCompressed AirNitrogenCO2
Air sampling should be done and tested for the presence of non-viables and viables by exposure to the environment
Pressure control orifices should be used to provide a steady stream of air
Fall out plate Slit sampler (slit-to-agar sampler)
Slit Sampler (New Brunswick Scientifics Model STA-230 Slit-to-Agar Air Sampler)
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Characterization of aseptic process The four pillars of a robust aseptic process
Personnel training amp monitoring Environmental monitoring Facilities design Media fills
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Personnel Training amp Monitoring Avoiding contamination means knowing the potential sources
of contamination Personnel Equipment Airliquids Drug product Containersclosures Outside environment
Anything Brought in contact with or in the vicinity of the product is a potential source of contamination
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Environmental Monitoring
The goal of the environmental monitoring program is to provide meaningful information on the quality of the aseptic processing environment during production as well as environmental trends
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
1
2
3 4
5
67
8
9 10
11
13
12
Environmental Monitoring
Critical (processing) areas
Sampling
Sampling of adjacent classified areas (aseptic corridors gowning rooms etc) will provide trenddata and may help identify sources of contamination
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Facilities General Clean room Design
HEPAULPA filters on ceiling Exhaust vents on floor Airlocks and interlocking doors to control air balance Seamless and rounded floor to wall junctions Readily accessible corners Floors walls and ceilings constructed of smooth hard
surfaces that can be easily cleaned Limited equipment fixtures and personnel Layout of equipment to optimize comfort and movement
of operators
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Facilities Clean room Classification
FS209 Cleanroom
classification
ISO 14644-1 Cleanroom
classificationge05um
particlesm3
Viable Microbes(cfum3)
Ave Airflow Velocity
(fpm)Air
changeshr
100000 8 3520000 100 5-10 5-48
10000 7 352000 10 10-15 60-90
1000 6 35200 7 25-40 150-240
100 5 3520 1 40-80 240-480
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Class 10000 clean room
httpwwwamericancleanroomscomamphotogallery_08html
Class 100 clean room
Facilities Clean room Classification
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Facilities HEPA Filters
httppeopledeasharvardedu~joneslab_archnano_facilitieshepagif
High Efficiency Particulate Air filters
Minimum particle collection efficiency 9997 for 03microm diameter particles
Disposable
Filter made of pleated borosilicate glass
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Media Fill test Used to validate the aseptic process
Use microbial growth media instead of drug product-any contamination will result in microbial growth
It doesnrsquot provide a direct relation for sterility but gives an adequate evaluation for operational processing steps
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Media and Incubation conditions
Soybean casein digest medium (SCD) Fluid thioglycollate medium (FTM) for anerobes
Inoculated with lt 100 cfu challenge At least 14 days incubation 30-35degC for SCD 20-25degC for FTM temperatures should be monitored product produces suspension flocculation or deposit in
media suitable portions (2-5) should be transferred to fresh media after 14 days and incubated for a futher 7 days
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
Theoretical Evaluation Whyte mathematical model contamination is due to air borne microbes
d = equivalent particle diameterA= area of container opening (cm2)
t = time (sec)
Cont rate (c) = 00032d2At
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
PostScript (conclusion)
The challenge in aseptic processing is always personnel
1048708 As a source of microbial andParticle contamination1048708As a brake on the implementation ofImproved technology
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
REFERENCES
Encyclopedia of pharmtechnology
RUSSELL A D Bacterial Spores and Chemical Sporicidal Agents clinical microbiology reviews 3(2) 99-119 (1999)
httpwwwfdagovcbergdlnssterasepticpdf
httpwwwemedicinehealthcomimages4453
httppathmicromedscedufoxlpsjpg
httpmicromedharvardedufacultyrudnerhtml
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-
ThanQ
- Schedule (contents)
- Aseptic Processing
- Slide 4
- Causes of sepsis Sterile drug manufacturers should have a kee
- Slide 6
- Producing drug products by
- Terminal Sterilization
- Aseptic Processing
- Contaminating agents
- Humans and bacteria
- Sources of Contamination
- Control 1st step ndash eliminating the source of contamination
- Gowning (sterile barrier)
- Slide 15
- Aseptic Technique (skill)
- Slide 17
- Slide 18
- Slide 19
- Slide 20
- Sporicidal agents
- Isolators
- Microbial Environmental Monitoring Identification
- Slide 24
- Slide 25
- Genotypic Methods
- Slide 27
- Slide 28
- Microbiological testing of water
- Microbiological testing of air
- Characterization of aseptic process The four pillars of a robu
- Personnel Training amp Monitoring
- Environmental Monitoring
- Slide 34
- Facilities General Clean room Design
- Facilities Clean room Classification
- Slide 37
- Facilities HEPA Filters
- Media Fill test
- Slide 40
- Theoretical Evaluation
- PostScript (conclusion)
- REFERENCES
- ThanQ
-