GMP compliant cleaning in the Pharmaceutical Industry. Andreas Trochsler 06. November 2012
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1 GMP compliant cleaning in the Pharmaceutical Industry Andreas Trochsler 06. November 2012
2 Topics Why GMP Cleaning? Prevention of Cross Contamination in Automated GMP Washer About Belimed 2 B-SAG November 2012 ATR
3 Why cleaning? Prevention of Cross Contamination between batches between products within the same factory / facility Prevention of drug contamination during manufacturing cycle Constant Guarantee of drug quality 3 B-SAG November 2012 ATR
4 Where is GMP cleaning necessary? General Production steps: Goods to be washed: Filtration / Grinding Shovels / Filters / Containers Weighing Containers / Funnels / Glassflasks Preparation / Mixing Hoses / Vessels / Bins Filling / Dosing Valves / Pumps / Trays Packing Packing 4 B-SAG November 2012 ATR
5 Cleaning Methods in GMP Facilities Manual Cleaning Clean-in-Place (CIP) Automated GMP Cleaning 5 B-SAG November 2012 ATR
6 Manual Cleaning Advantage Very large pieces Very small pieces Fragile pieces Disadvantage Water consumption Difficult to validate Difficult repeatability Long cleaning time 6 B-SAG November 2012 ATR
7 Clean-in-Place Advantage Large pieces of equipment directly cleaned in place without disassembling Time saving (often directly ready to use) Disadvantage Difficult installation Difficult validation Big amount of water needed Cost of cleaning device 7 B-SAG November 2012 ATR
8 Automated GMP Cleaning Advantage Reproducibility Possibility to validate the washer Possibility to record the cycles Different cycles for different wash exercises Different racks for different wash goods Water saving Disadvantage Space requirements Investment cost 8 B-SAG November 2012 ATR
9 Elements of Automated Cleaning Load Carrier (rack) Parts to Clean Washer Cleaning Process 9 B-SAG November 2012 ATR
10 Example of a Washing machine Belimed PH840 Usable cabin dimensions (mm) H 990 x W 830 x D 830 Cabin volume 682 L, Tank volume 60 L Easy to clean exterior Design Stainless steel cabinet, in Pharma No. 4 brush finish Ra 1,0 µm 10 B-SAG November 2012 ATR
11 Flow Scheme of Cleaning System Pipes F2 VL1 F1 V2 AIR Heat Exchanger Top Nozzles (Spinning Spray Arm) V5 Heating Drying Air Wash Cabin WATER Internal Spraying (Direct Injection Cart Docked) V1 Inlet Bottom Nozzles (Spinning Spray Arm) Tank Heating V4 V3 P1 Simplified drawing e. g. w/o dosage, additional media, blow-out, GMP final rinsing 11 B-SAG November 2012 ATR
12 Flow Scheme of Cleaning System Filling of Tank Pipes F2 VL1 F1 V2 AIR Heat Exchanger Top Nozzles (Spinning Spray Arm) V5 Heating Drying Air Wash Cabin WATER Internal Spraying (Direct Injection Cart Docked) V1 Inlet Bottom Nozzles (Spinning Spray Arm) Tank Heating V4 V3 P1 Simplified drawing e. g. w/o dosage, additional media, blow-out, GMP final rinsing 12 B-SAG November 2012 ATR
13 Flow Scheme of Cleaning System Cleaning Pipes F2 VL1 F1 V2 AIR Heat Exchanger Top Nozzles (Spinning Spray Arm) V5 Heating Drying Air Wash Cabin WATER Internal Spraying (Direct Injection Cart Docked) V1 Inlet Bottom Nozzles (Spinning Spray Arm) Tank Heating V4 V3 P1 Simplified drawing e. g. w/o dosage, additional media, blow-out, GMP final rinsing 13 B-SAG November 2012 ATR
14 Flow Scheme of Cleaning System Drying Pipes F2 VL1 F1 V2 AIR Heat Exchanger Top Nozzles (Spinning Spray Arm) V5 Heating Drying Air Wash Cabin WATER Internal Spraying (Direct Injection Cart Docked) V1 Inlet Bottom Nozzles (Spinning Spray Arm) Tank Heating V4 V3 P1 Simplified drawing e. g. w/o dosage, additional media, blow-out, GMP final rinsing 14 B-SAG November 2012 ATR
15 GMP Compliant Design Automatic Full-Glass Door Automatic, sliding glass door for easy visual inspection Guide rail Pneumatic door seal with lateral seal valve Vertical or Horizontal door opening Door actuation with friction wheel Sliding door Linear drive with spindle Force in case of failures < 150 N according to legal requirements (ZH1 / 494) Friction wheel Guide rail Sliding door 15 B-SAG November 2012 ATR
16 GMP Compliant Design Piping / Valves Single pipe system for washing, rinsing, drying to prevent cross contamination Completely self draining, installation with 2-4% slope No dead ends Pneumatic actuated aseptic diaphragm valves self drainable inbuilt 16 B-SAG November 2012 ATR
17 GMP Compliant Design Pipe Fittings Sterile Neumo BioConnect flanges instead of conventional TriClamp connections Neumo BioConnect TriClamp Centric guiding prevents off-set of wetted areas Centric guiding of connection by gasket: off-set possible Metal-to-metal-stop avoids stress or overcompression of gaskets (O-ring) Defined, symmetric compression of gasket No metal-to-metal-stop Undefined, asymmetric compression of gasket Wetted seal area 50% smaller 17 B-SAG November 2012 ATR
18 GMP Compliant Design Wash Cabin and Tank Cabin and tank interior in mirror sheet metal with round corners (20 mm radius), no dead legs and crevice free Inclined surfaces (e. g. chamber floor and roof, piping) No guard plates No threaded fittings Weld seams smoothed and polished Surface roughness Cabin surface Ra 0.4 µm Weld seams Ra 0.8 µm 18 B-SAG November 2012 ATR
19 GMP Compliant Design Rotating Spray Arm
20 GMP Compliant Design Connection of Internal Spraying Automatic docking of direct injection carts No dead legs, low surface roughness Pneumatic system for optimum sealing No pressure reduction, no loss off water (4) (1) (3) (2) (1) Quick Coupling Connector (cart) (2) Quick Coupling Connector (cabin) (3) O-Seal with FDA approval (4) Counter bearing (cabin) Druckluft Compressed (2,4bar) air Media Medien (max. 1,8bar) Water/Air (Wasser/Luft) Druckluft Compressed (2,4bar) air 20 B-SAG November 2012 ATR
21 GMP Compliant Design Wash Pump Sterile pump (vertical installation) 3A2 sterile standard Pump casing with no dead legs Crevice-free seal surfaces Sterile seals Surface roughness Ra 0.8 µm Complete drainable 21 B-SAG November 2012 ATR
22 GMP Compliant Design Dosing Unit Precise dosing of detergent via dosing head Rotating spray arm rinses dosing head Reduction of the number of openings in the cabin Use of diaphragm valves prevents dripping Spray arm Dosing head 22 B-SAG November 2012 ATR
23 GMP Compliant Design Integrated Drying Air duct into the cabin, into the carts and into the pipes Feed Pipe Box E-Heating Sterile Filter Temperature control by PLC and PT 100 sensor class A Preliminary filter F9 and sterile filter H13/H14 Standardized filter test device with scan option via DEHS fitting Differential pressure measurement for monitoring of fan and filter function Fan Preliminary Filter DEHS Fitting Flange 23 B-SAG November 2012 ATR
24 GMP Compliant Design Self-Cleaning Performance Test cleaning process w/o neutralization: Conductivity (µs) of waste water 10 3 min 10 min 3 min 3 min 3 min 3 min 3 min 3 min 15 min Pre-rinsing with recirculation of cold purified water Cleaning with recirculation 60 C of NaOH solution 2% Rinsing I with recirculation of cold purified water (12µ S) Rinsing II with recirculation of cold purified water Rinsing III with recirculation of cold purified water Final rinsing I with recirculation of cold DI water (1,5µ S) Final rinsing II with recirculation of cold DI water Final rinsing III with recirculation of hot DI water 80 C Drying 110 C Initial conductivity of fresh WFI water is achieved DI Water Final Rinse I Final Rinse II Final Rinse III 24 B-SAG November 2012 ATR
25 Belimed Group Infection Control 1 Group: Belimed Group AG, Switzerland 4 competence centers (CH, D, SI) Total number of employees: approx 990 Total turnover 2011:195.0 Mio. CHF GMP-compliant steam sterilizers from to ( L) GMP-compliant cleaning systems from PH820 PH880 ( L) Over 40 years experience in cleaning and sterilization in the healthcare, pharmaceutical and laboratory sectors ( installations) 25 B-SAG November 2012 ATR
26 26 B-SAG November 2012 ATR
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