SOP-for-Process-Validation
SOP-for-Process-Validation
1.0 OBJECTIVE:
To lay down a Procedure for Process Validation.
2.0 SCOPE:
This SOP is applicable to all products manufactured at ……………………
3.0 RESPONSIBILITY:
QA (Officer/Executive): Preparation, Distribution (to Respective Department), Revision, Retrieval and
Destruction of this SOP.
QA Manager: Review, Approval, Training and effective implementation of this SOP in all the
applicable areas.
Production & QC: Effective implementation of the Procedure
4.0 ACCOUNTABILITY:
Head QA: Approval of this SOP & ensure Training and effective Implementation of SOP.
5.0 DEFINITION:
Process Validation is documented evidence which provides a high degree of assurance that a specific
process will consistently result in a product that meets its predetermined specifications and quality
characteristics”.
6.0 PROCEDURE:
6.1 TYPES OF PROCESS VALIDATION:
6.1.1 PROSPECTIVE PROCESS VALIDATION:
“Validation carried out during development stage or before the Commercial Production”
6.1.2 CONCURRENT PROCESS VALIDATION:
“Validation carried out during routine production of products intended for sale”.
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
6.7.3 Initiator shall check the completeness of draft Process Validation Protocol and Report and send
the hardcopy to the different Departmental Heads (Head-Production, Quality Control &
Engineering) for review.
6.7.4 Draft Process Validation Protocol and Report hardcopy shall be send to customer for review (if
required).
6.7.5 On receipt of the comments (if any), the same shall be reviewed and incorporated in the Process
Validation Protocol and Report after discussion with Head-QA.
6.7.6 The draft Process Validation Protocol and Report after completion of checking and incorporation
of comments or suggestions as agreed, shall be destroyed, this shall be done in concerned
Originating Department.
6.7.7 Master Copies of all Process Validation Protocol and Report shall be printed in QA Department
only.
6.7.8 No manual correction shall be made in Approved Copy (Master / Controlled Copy).
6.7.9 Procedure for Preparation, Validation/Qualification Protocol and Report is given in SOP.
6.7.10 Storage of Process Validation Protocol and Report (Master Copy):
All Master Copy of Approved Process Validation Protocol and Report shall be stored in QA
Department.
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
VALIDATION
PROTOCOL
PREPARATION
INPUT REVIEW
RECORDS
CHECK QUALIFICATION OF
EQUIPMENT, ENVIRONMENT,
UTILITY, RM & PM
EXECUTION OF ACTIVITY
COMPLIANCE OF ACCEPTANCE
CRITERIA
REPORT REVIEW
APPROVAL
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
ACTIVITY
PROTOCOL PROTOCOL
PROTOCOL PROTOCOL & REVIEW
REPORT REVIEW
REVIEW
PREPARATION /
REVIEW
VALIDATION
SUPPORT SAMPLE
SUPPORT FOR SERVICES ANALYSIS
VALIDATION PROTOCOL
ACTIVITY APPROVAL
RESULTS
SUBMISSION
PROTOCOL
TRAINING TO
VALIDATION VALIDATION REPORT
REPORT
EXECUTION TEAM REVIEW
REVIEW
MONITORING PROTOCOL
REPORT COMPLETENESS &
REVIEW TECHNICAL ACCURACY,
SAMPLING & EXECUTION
OF VALIDATION ACTIVITY
REPORT
REVIEW
REPORT
APPROVAL
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
6.11.4 The Protocol should specify a sufficient number of replicate process runs to demonstrate
Reproducibility and provide an Accurate Measure of Variability among Successive Runs.
6.11.5 The test conditions for these runs should encompass Upper and Lower Processing Limits and
Circumstances, including those within Standard Operating Procedures, which pose the greatest
chance of Process or Product Failure compared to ideal conditions.
6.11.6 Key Process Variables should be monitored and documented.
6.11.7 Analysis of the data collected from monitoring will establish the variability of process parameters
for individual runs and will establish whether or not the equipment and process controls are
adequate to assure that product specifications are met.
6.11.8 Trend in the process should be monitored to ensure the process remains within the established
parameters. When monitoring data on quality characteristics demonstrates a negative trend, the
cause should be investigated, corrective action may be taken and revalidation considered.
6.11.9 Any change in the Process and/or Product including changes in Procedures, Equipment, and
Personnel etc should be evaluated to determine the affects of those changes and the extent of
Revalidation considered.
6.11.10Various changes may occur in Raw materials and/or Processes, which are undetected, or
considered at the time to be inconsequential. These changes may cumulatively affect the
validation status of the process. Periodic Revalidation should be considered for these types of
processes.
6.12 PROCESS VALIDATION TEAM:
Members of the Validation Team shall include representatives from:
Quality Assurance
Production
Quality Control
Engineering
6.13 PROCESS VALIDATION FOR LIQUID INJECTIONS IN AMPOULES:
6.13.1 Critical Process Variables:
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
Following are the Critical Process Variables which are to be validated during Process Validation
but not limited to:
Washing and Sterilization of Sterile Garments: Washing Time, Sterilization Time,
Sterilization Temperature Range, Sterilization Hold Time etc.
Cleaning and Sterilization of Equipments: Washing Time, Sterilization Time, Sterilization
Temperature Range, Sterilization Hold Time etc.
Preparation of Bulk Solution: Mixing Time, Mixing Speed, Process Time & Capacity of the
Mixing Vessel etc.
Filtration of Bulk Solution: Pre & Post Integrity of Filters, Process Time etc.
Ampoule Sterilization and Depyrogenation: Process Time, Conveyor Speed, Conveyor Start
Temperature, Sterilization Time, Sterilization Temperature Range Sterilization Hold Time etc.
Empty Ampoules: Sterility, BET, Physical Observation etc.
Filling and Sealing: Differential Pressure in Sterile Area, Temperature, Relative Humidity
Process Time, Machine Speed, Fill Volume, Hopper/Tank Level Qualification, Pressure
reading of Nitrogen, Sealing Inspection, Clarity, Leak Test etc.
Visual Inspection of Filled Ampoules: Physical Defects i.e. Deformation, Black or White
Particles, Volume Variation, Clarity, Fibers etc.
Packing: Packing Style, Quality and Quantity of Packing etc.
6.13.2 Sampling and Analysis Plan:
Following are the Sampling and Analysis Plan during Process Validation but not limited to:
Preparation of Bulk Solution: Description, pH, Identification Assay, Weight/ml, Bioburden
etc.
Filtration of Bulk Solution: Sterility etc.
Ampoule Sterilization and Depyrogenation: Conveyor Start Temperature Conveyor Speed
Sterilization Hold Time etc
Empty Ampoules: Sterility, BET, Physical Observation etc.
Filling and Sealing: Extractable Volume, Description, Identification, Particulate Matter, pH
Assay, Sterility, BET etc.
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
Visual Inspection of Filled Vials: Physical Defects i.e. Deformation, Black or White
Particles, Volume Variation, Clarity, Fibers etc.
Packing: Packing Style, Quality and Quantity of Packing including coding Quality etc.
6.14.2 Sampling and Analysis Plan:
Following are the Sampling and Analysis Plan during Process Validation but not limited to:
Preparation of Bulk Solution: Description, pH, Identification Assay, Weight / ml, Bioburden
etc.
Filtration of Bulk Solution: Sterility etc.
Washing & Sterilization of Rubber Bungs: Sterility, Visible Observation, Bacterial
Endotoxin Test, Moisture Content etc.
Sterilization of Aluminium Seals: Sterility, Visible Observation, Bacterial Endotoxin Test,
Bioburden etc.
Washing & Sterilization of Vials: Clarity, Visible Observation, Sterility, Bacterial Endotoxin
Test etc.
Filling and Sealing: Description, Sterility Test, Bacterial Endotoxin Test, Particulate Matter,
pH, Water Content, Assay, Identification, Extract Volume, Volume Variation etc.
Packing: As per Finished Product Specification
6.14.3 Sample Quantity:
Quantity of the Samples shall be withdrawn as per the quantity mentioned in the respective
Process Validation Protocol.
6.14.4 Sampling Location:
Samples shall be withdrawn as per the locations mentioned in the respective Process Validation
Protocol.
6.15 PROCESS VALIDATION FOR THREE PIECE ( EYE / EAR DROPS):
6.15.1 Critical Process Variables:
Following are the Critical Process Variables which are to be validated during Process Validation
but not limited to:
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
Quantity of the Samples shall be withdrawn as per the quantity mentioned in the Respective
Process Validation Protocol.
6.15.4 Sampling Location:
Samples shall be withdrawn as per the locations mentioned in the respective Process Validation
Protocol.
6.16 PROCESS VALIDATION FOR DRY POWDER INJECTION:
6.16.1 Critical Process Variables:
Following are the Critical Process Variables which are to be validated during Process
Validation but not limited to:
Washing and Sterilization of Sterile Garments: Washing Time, Sterilization Time,
Sterilization Temperature Range, Sterilization Hold Time etc.
Cleaning and Sterilization of Equipments: Washing Time, Sterilization Time, Sterilization
Temperature Range, Sterilization Hold Time etc.
Washing & Sterilization of Rubber Bungs: Process Time, Sterilization Time, Sterilization
Temperature Range, Sterilization Hold Time etc.
Sterilization of Aluminium Seals: Process Time, Sterilization Time, Sterilization
Temperature Range, Sterilization Hold Time etc.
Washing & Sterilization of Vials: Process Time, Speed of Washing Machine, Pressure of
Water and Compressed Air, Conveyor Speed, Conveyor Start Temperature, Sterilization Time,
Sterilization Temperature Range Sterilization Hold Time etc.
Filling and Sealing: Differential Pressure in Sterile Area, Temperature, Relative Humidity
Process Time, Machine Speed, Hopper Level Qualification, Fill Weight, Pressure reading of
Nitrogen, Sealing Inspection, Clarity, Leak Test etc.
Visual Inspection of Filled Vials: Physical Defects i.e. Deformation, Black or White
Particles, Weight Variation, Clarity, Fibers etc.
Packing: Packing Style, Quality and Quantity of Packing including Coding Quality etc.
6.16.2 Sampling and Analysis Plan:
Following are the Sampling and Analysis Plan during Process Validation but not limited to:
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
6.20 The Validation Batches may be commercialized on the basis of satisfactory Stability Data (Three / Six
Month Accelerated Stability Study) for the product. However Stability Studies are continued and
reviewed periodically.
7.0 ABBREVIATIONS:
BET Bacterial End toxin Test
DQ Design Qualification
F&D Formulation & Development
LDPE Low Density Poly Ethylene
LOD Loss on Drying
Ltd. Limited
PM Packing Material
QA Quality Assurance
QC Quality Control
RH Relative Humidity
RM Raw Material
SS Stainless Steel
STP Standard Test Procedure
8.0 ANNEXURES:
Not applicable
9.0 DISTRIBUTION:
Controlled Copy No. 01 Head Quality Assurance
Controlled Copy No. 02 Head Quality Control
Controlled Copy No. 03 Head Production
Master Copy Quality Assurance Department
STANDARD OPERATING PROCEDURE
Department: Quality Assurance SOP No.:
Title: Process Validation Effective Date:
Supersedes: Nil Review Date:
Issue Date: Page No.:
10.0 REFERENCES:
USFDA CDER: Guidance for Industry Process Validation: General Principles and Practices
Schedule-M
Validation Master Plan
PIC’s Guidelines
SOP, Titled “PREPARATION OF VALIDATION/QUALIFICATION PROTOCOL AND
REPORT.