Media Filling Process in Pharma Industry
Material
issue as per FO (Formulation Order)
Material transfer into critical area (sterile lactose)
|
Liquid media preparation
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Resealing of lactose bags
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Check pH
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Dispensing and blending with intervention simulation
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Sterilize the m/c parts, rubber stoppers , dispensing
aids, media garments and bin
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m/c
parts assembling ( filling) , bin , connection on the day of media filling
Media
filling parts assembling and liquid media connection to filling m/c
Vial
washing and sterilization
Media Checking for Growth
- Lactose and liquid media filling stoppering
- Sealing, crimping of aluminum seal ( sample for sterilize
media for GPT, vials , rubber stoppers , compressed air sterility test / viable
commit monitoring)
- Labeled tray with date / time and other details
- Collect the vials in tray, transfer and handover to micro
dept. for incubation through temp. controlled van (truck)
Preparation
of Media
·
Prepare 3% solution of media
·
30gm SCDM (soybean casein digest
media) + 1000ml (qs) of wfi (Water For Injection) dissolve in glass carboy.
·
Collect the media sample for pH
testing using pH meter and adjust the pH if require.
·
Labeled the media , date of
preparation and exp date of media should be 7 days from the date of mfg (Manufacturing Date).
·
Plug the carboy with cotton plug and
wrap with breathable cloth sterilize the carboy glass.
·
After sterilization unload the glass
carboy in cooling zone and store under UAF on SS table (Stainless Steel Table).
·
Transfer the media carboy to vial
filling room through the UAF mounted mobile trolley.
·
End of operation collect the media
solution from each carboy and send to micro lab for GPT.
·
Incubate the media in micro lab for
7 days at 20⁰C to 25⁰C followed by 7 days at 30⁰C to 35⁰C.
·
Record the observation in
microbiology validation green sheet.
GPT
Growth
Promotion Test, to insure that the liquid media used for the process
simulation test is capable of microbial growth promotion.
Lactose
Powder
Sterilized by
gamma radiation method Lactose transfer in critical area
· Gamma radiation sterilized powder of lactose => qc (quality Control)
released => clean with lint free wipe
· Outer carton and polybag removed in material transfer
airlock
· Pack sanitized and enter into pass box
· Critical area
· Lactose bags shall open inside the RABS (restricted access
barrier system)
Dispensing Procedure
· Lactose passes through mesh 36 over the ss-bin using the
spoon
· Load the bin on mixing column
· Blend for 30 min
· Unload the bin and transfer it into RABS
· Remaining quantity also passed by same procedure
· Quadruplet sampling carried out from 10 location (don’t take
out sample only simulate)
· Simulate pulled sample collection from 3 location (twice)
for bulk analysis
· Transfer the bulk containing lactose for vial filling
operation
Assembling Vial Filling m/c Parts
· Assembled the liquid media filling parts ( peristaltic pump
with needles and silicon hose )
· SS bin containing sterilize lactose
· Upload it with lifting column
· SS bin connect to powder hopper chute of vial filling m/c
· Assembling the pre end post air flushing assembly
· Insure that vials are flushed with sterile ( filtered )
compressed air during the filling process
· 30/40 ml vial – 50ml volume ( 250mg lactose) filled
· 100ml vial – 10ml volume ( 500mg lactose) filled
· Minimum vial quantity to be put for incubation in each media
fill operation shall not be less than 10,300 vials ( applicable for all pack
sizes )
· Record the collection time of media filled vials on each
tray / boxes and affix the label
USE of Sterilize Lactose
· Flow ability through the hopper and dosing wheel is similar
to the product manufacture
· It does not inhibit the growth of microbes and has growth
promotion activity
· Soluble in media and water
· Sterilized by gamma radiation
Incubation Period
· 7 days ( bacterial growth ) – 20 to 25⁰C
· 7 days ( viral growth ) – 30 to 35⁰C
· Total 14 days incubation.
1. 30/40ml vials 5500 to 6500
vials/hrs., lactose filled using single dosing mechanism
2. 100ml vials 2500 to 3500
double dosing wheel mechanism
Post Media-fill Activity
· Clean and sanitize the equipment (used for media fill
activity)
· The final rinse sample (from product contact part) should be
analyses for TOC
· The TOC in the rinse water sample shall not exceed 500ppb
Vial
|
Stopper
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Seal
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30ml
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20mm
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20mm
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40ml
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20mm
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20mm
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100ml
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28mm
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28mm
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Tubular
vial
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Bromobutyle
rubber stopper
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Flip
off
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Media-fill
Failure
· In case of media fill failure respective procedure of OOS (
out of specification) in microbiological analysis , investigation , deviation
management shall be followed
· Characterization of microorganism up to species level shall
be carried out to find out the sources of contamination
· Environmental records for manufacturing and testing area for
temp. RH , DP and non-viable air born particle counts
· Microbiological monitoring, reports of manufacturing and
testing area for settling plate air sampling, surface monitoring and personnel
monitoring.