Pda guideline for media fill

Those sterile dosage forms that are stable only for a short time in solution are frequently marketed in lyophilized presentations see Figure 3. The process is more complicated than standard vial filling, although it may involve many items of common equipment.

Vials are aseptically filled in the normal way, but the closures which are of a special design are not fully inserted. The filled, partially stoppered vials are "trayed," taken and loaded into a lyophilizer. The traying and transfer of the vials from the filling machine to the lyophilizer may be done manually or automatically e. Irrespective of the means, the contents of the vials are vulnerable to contamination while they are only partially stoppered.

Within the lyophilizer the liquid in the vial is frozen and a vacuum drawn. The water from the solid frozen phase sublimes directly to vapour, and the dosage form dehydrates. At the end of the cycle the vacuum is broken and the closures are automatically rammed home.

The main vulnerability of the process to microbiological contamination is clearly at the point where the vacuum is broken and air enters the lyophilizer and the vials. Replacement air must be filtered sterile, but other undiscovered means of air contamination from leaks, bypasses, etc. The aseptic filling process should be simulated exactly as any other vial-filling process.

However, since the closures and the vials may differ, attention should be given to simulating any activities that are peculiar to filling lyophilized vials as distinct from liquid-filled vials. There may be a greater frequency of intrusion to free blocked closure chutes, or to remove vials that have fallen over.

Any such difference will be unique to the particular process and have to be determined empirically. Those who argue that lyophilization is one of the most frequently used methods of preserving microorganisms and is therefore not inimical, have clearly never experienced the difficulties that microbiologists endure and overcome to ensure viability when using lyophilization for preservation purposes. Freezing should not be simulated: 24 of 26 manufacturers using lyophilization who responded to the PDA's survey of aseptic manufacture claimed not to freeze their media fill vials PDA, If there is danger of unfrozen media foaming over under vacuum and thus contaminating the lyophilizer, it may be necessary to double the size of the media fill.

Simulate all of the risks up to and including loading of the freeze dryer in one-half of the media fill that is not frozen, and then simulate the subsequent risks with the rest of the filled vials that are passed through the complete process including freezing.

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In addition to the technical difficulties of foaming, which would happen if a complete vacuum were to be drawn over the liquid rather than solid-phase dosage form, consideration should be given to any fluid loss from the media and its effect on the viability of microorganisms and the ability of the media to support microbial growth.

These are two separate issues. After some concentration the media may still be able to support the growth of microorganisms, but injured microorganisms may have died as concentration took place. Typically, a partial vacuum of say 20 to 28 inches Hg is drawn, held for about two hours and "broken.

Some companies perform complete simulation of the lyophilization process from filling, through transfer, to lyophilization. Others may split the process into three simulations to help provide a clearer focus on what might have gone wrong if contaminated units result from the media fill. The decision as to which approach to take or how to develop a responsible combination of the two approaches is a matter of judgement. A balance has to be struck between regulatory pressure to simulate the process as closely as possible, and the need also pursued rigorously by regulatory inspectors to diagnose the source of contamination accurately enough to implement satisfactory corrective or preventive actions.

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Get My Free Ebook. Herbal Remedies For Acid Reflux Gastroesophageal reflux disease is the medical term for what we know as acid reflux.My company plan to do media fill so i want to know the routine and non routine intervention use during media fill.

Dear sir, please explain why sterile lactose is filled in the vials during medial fill. Hi Mohammad, it is strongly recommended that media fill shall be performed in the clear transparent bottles. How can I justify production batches before media fill if one unit show growth in semi annual media fill. In case of re validation of media fill study on semi yearly basis if we would have a risk assessment study along with initial complete validation and worst case consideration study and then if we plan to consider most risky pack size for re validation on semi yearly basis does it complies with compendium and regulatory guidelines?

Plz let me know in these regards. Hi TK saha, it is find to have bracketing or matrix approach for re-validation of media fills on semi yearly basis, however it is mandate to perform media fill for all pack sizes when you are introducing a new pack into the line. Hi, I have a weird question, why do we use SCDM only, why cannot other medias were used for media fills.

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Anticipating for quick response. Home Protocol Sterile Validation. Ankur Choudhary Print Question Forum 12 comments. The bulk is then aseptically filtered into a sterile holding tank under LAF in the sterile area. Three runs will be validated with mg sterile lactose and 5 ml media solution, mg sterile lactose with 5 ml media solution and mg sterile lactose with 10 ml media solution to validate the weight range from mg to mg.

Imitate maintenance activities that are likely to take place during routine filling process, after restarting approx. After the incubation period of the media-filled containers, they are visually examined for microbial growth.

Damaged containers should not be included as failures positives when evaluating results.


The number of containers used for media fills should be sufficient to enable a valid evaluation. For small batches, the number of containers for media fills should at least equal the size of the product batch. The target should be zero growth and the following should apply:. Pin it. Ankur Choudhary is India's first professional pharmaceutical blogger, author and founder of Pharmaceutical Guidelines, a widely-read pharmaceutical blog since Sign-up for the free email updates for your daily dose of pharmaceutical tips.I mean sterility testing for anaerobic organisms required or not?

Hallo How we can do to detect the residues of TSB growth medium after cleaning of equipement? Dear sir As per interpretation of results, please tell me the difference in between filled units and filled units.

As per the above information if we find 2 contaminated vials in both conditions we should re-validate the media fill. Can you explain please. Home Microbiology Sterile Validation.

Media Fill Validation -SVP Learn how to validate the aseptic filling process and validation protocol for Media Fill Validation in aseptic pharmaceutical processing and acceptance criteria. Ankur Choudhary Print Question Forum 6 comments.

This process of validation also known as a media fill validation, normally includes exposing the microbiological growth medium to product contact surface of equipment, container closure system, and critical environments to closely simulate the same exposure that the product itself will undergo at the time of processing or filling. The sealed containers after filling with the medium are incubated to detect microbial growth for contamination at optimum temperature.

Name of the Department. Preparation of Protocol. Approval of protocol. Quality Assurance. Final determination of System Acceptability. Review and assembling of data into a final report. Technical Support. Production and Engg. Ankur Choudhary is India's first professional pharmaceutical blogger, author and founder of Pharmaceutical Guidelines, a widely-read pharmaceutical blog since Sign-up for the free email updates for your daily dose of pharmaceutical tips.

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Visitors are also reading:. You can ask questions related to this post here. Unknown 09 May. Unknown 13 April. Ankur Choudhary 13 April. Unknown 02 January. Unknown 22 April. Manoranjan 03 December. Get Free Updates Subscribe. View adsbypg. Recent Posts. Join Log In 8. Verification of Protocol.A survey of FDA Form observations issued to the B pharmacy industry reveals that outsourcing compounders are struggling to implement and manage compliant and risk-based approaches to aseptic process simulation studies APScommonly referred to as media fills.

The following are typical observations:. These observations have a similar theme that the design and performance of aseptic process simulation APS studies are not representative of the most challenging compounding operations with the worst-case conditions being considered. A matrix approach to APS studies can help to identify the most challenging compounding operations. The first step in developing an APS matrix is to identify the major product categories that are compounded within the pharmacy.

The goal is to assign all compounded products into as few categories as possible using sound scientific rationale. After the products have been categorized, the second axis of the matrix is populated with process variables that represent actual compounding conditions. The objective is to identify a range of conditions that, when combined, could contribute to the contamination of the product and represents the highest potential for risk. The following represents a few typical examples:.

After the matrix variables have been defined, populate the matrix and identify worst case processes. Now that the worst-case processes have been defined with an APS matrix, it is possible to go even further to challenge the process by identifying potential interventions that could impact sterility. Because manual aseptic processing relies heavily on personnel interventions, these practices present a challenge to control and depend heavily on procedures, training and technique to manage the risk.

Representative interventions should be challenged for each APS and include inherent and corrective human action, such as glove changes, making tubing connections, technician breaks, removing components from the direct compounding area, etc. After your risk-based APS program has been developed, the key is to document all the criteria and justification for worst-case conditions in a protocol or SOP. If the matrix determines more than one product or process to be of considerable challenge, a rotating semi-annual requalification schedule may be established.

It is possible to consolidate the myriad of compounded products and develop a risk-based, matrix program to identify potential weaknesses that may contribute to contamination of the compounded products. Hi Sign up Login. The following are typical observations:Your media fill studies do not closely The following are typical observations: Your media fill studies do not closely simulate aseptic manufacturing operations incorporating, as appropriate, worst-case activities and challenging conditions.

In manually intensive filling processes, a large number of media fill units, generally approaching the full production batch size, should be used. Maximum number and type of manual manipulations that are typically performed during the operation. Read next. Company Products.Definition of Media Fill and Requirements of the Guidelines: — According to all guidelines the process simulation with media fill is state of the art for the validation of aseptic manufacturing process.

Media fill means that a microbiological nutrient media will be filled into a container closure system ampule, vials etc instead of the product under simulation of aseptic standard procedure. The filled container closure systems are incubated under defined parameters and finally checked for microbiological contamination. This is to demonstrate that rooms, equipment and personnel are able to manufacture a product with very low contamination rate.

All manufacturing procedures in pharmaceutical industry must be validated. Choice of the Media Fill:- A microbiologically appropriate nutrient is to be used.

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Within pharmaceutical industries Soya-bean casein digest medium aerobe microorganisms and thioglycollate anaerobe microorganisms have been verified. Both media relate to the quality control of pharmaceutical medicinal products because of their use in sterility testing. The growth. The anaerobe simulation is restricted for filling lines which are used for products filled in an atmosphere where oxygen is excluded.

The absence of germs of Bovine Spongiforme Encephalopathy BSE is to be mandatorily demonstrated in case of every nutrient. Media Fill and Filling Volume:- Some points regarding the filling volume have to be considered Preparation of Media Fill:- The nutrient medium must be processed, handled, and filled in a manner that precisely simulates the normal manufacturing process. Thus, the normal manufacturing process has to be analysed. In media fill validation, dried nutrient medium base and Water for Injection WFI are used as the compounding starting materials.

Bioburden counts and determinations of endotoxin content, as well as analysis of pathogenic contaminants, for e. Pseudomonas aeruginosa or Echerichia coliare performed as in-process controls on the raw materials. Media fill should be prepared considering the instructions of the manufacturer regarding the usual manufacturing process for example using the sterile filter systems as appropriate.

Worst Case Simulation:- The simulation should consider such conditions which simulate the highest risk worst case of maximum expected and permitted loads. Examples for worst case conditions are defined in ISO For vial dimension and filling speed the worst condition is the biggest vial with the longest filling time, the widest-neck vial and the smallest vial with the highest speed.

pda guideline for media fill

Interventions:- All interventions and measures of the usual process should be simulated in media fill. Even technical interruptions should be considered lack of air system, stopping of the machine.

The approach is done during risk analysis with cooperation from the following departments: production, quality, validation, quality assurance. For small batch sizes for example products used for clinical trials at least the actual batch size should be simulated during media fill. The vials with the smallest and the biggest size should be regarded in media fill. The units in media fill shall be enough to simulate worst case conditions. Duration of Process, Holding Times and Stopping Times:- Time limits should be established for each phase of aseptic processing.

Time limits should include for example the period between the start of bulk product, compounding and its filtration, filtration processes, product exposure while on the processing line, and storage of sterilised equipment, containers and closures. Bioburden and endotoxin load should be assessed when establishing time limits for stages such as formulation processing stage. The total duration of the procedure consists of the time needed for the preparation of the bulk, time between the beginning of the preparation and the end of the sterile filtration.

The whole filling time should be simulated, but it is possible to stop the machine to avoid excessive numbers of filled units. Holding times e. The validation of such times is performed during media fill and then simulates worst case conditions.

pda guideline for media fill

For small batch sizes for example products for clinical trial at least the actual batch size should be simulated during media fill GMP Guide Annex ISO requires at last 5, units for the primary qualification of the process with three or more runs.Do the CGMPs require a firm to retain the equipment status identification labels with the batch record or other file? Assuming each major piece of equipment has a unique cleaning and use log that is adequately retained, is it acceptable to discard these quick reference equipment labels?

The CGMP regulations for finished pharmaceuticals require the retention of cleaning and use logs for non-dedicated equipment, but no similar requirement exists for retaining what are intended to be quick reference or temporary status labels.

We see no value in the retention of such labels in addition to the required equipment log or batch record documentation.

pda guideline for media fill

The labels serve a valuable, temporary purpose of positively identifying the current status of equipment and the material under process. Any status label should be correct, legible, readily visible, and associated with the correct piece of equipment.

The information on the temporary status label should correspond with the information recorded in the equipment cleaning and use log, or the previous batch record for nondedicated equipment. Labels are merely one way to display temporary status information about a piece of equipment. It is considered acceptable practice to display temporary equipment status information on dry-erase boards or chalkboards.

And it would be appropriate for an FDA investigator to verify that the information on a temporary status label is consistent with the log. Can containers, closures, and packaging materials be sampled for receipt examination in the warehouse? Generally, we believe that sampling in a typical drug manufacturing facility warehouse would not represent a risk to the container or closure or affect the integrity of the sample results. But whether the act of collecting a sample in the warehouse violates the CGMP requirement that containers "be opened, sampled, and sealed in a manner designed to prevent contamination of their contents For containers or closures purporting to be sterile or depyrogenated, sampling should be under conditions equivalent to the purported quality of the material: a warehouse environment would not suffice see 21 CFR This is to preserve the fitness for use of the remaining containers or closures as well as to ensure sample integrity, if they are to be examined for microbial contamination.

Media Fill - Basic

At a minimum, any sampling should be performed in a manner to limit exposure to the environment during and after the time samples are removed i. Well-written and followed procedures are the critical elements. Once a supplier's reliability has been established by validation of their test results, a manufacturer could perform the visual examination entirely in the warehouse. A firm has multiple media fill failures. They conducted their media fills using TSB tryptic soy broth prepared by filtration through a 0.

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Investigation did not show any obvious causes. What could be the source of contamination? A firm had multiple media fill failures. The media fill runs, simulating the filling process during production, were conducted inside an isolator.

The firm used TSB nonsterile bulk powder from a commercial source and prepared the sterile solution by filtering through a 0. An investigation was launched to trace the source of contamination. The investigation was not successful in isolating or recovering the contaminating organism using conventional microbiological techniques, including the use of selective e. The contaminant was eventually identified to be Acholeplasma laidlawii by using 16S rRNA gene sequence.

The firm subsequently conducted studies to confirm the presence of Acholeplasma laidlawii in the lot of TSB used. Therefore, it was not a contaminant from the process, but from the media source. Acholeplasma laidlawii belongs to an order of Mycoplasma. Mycoplasma contain only a cell membrane and have no cell wall. They are not susceptible to beta-lactams and do not take up Gram stain. Individual organisms are pleomorphic assume various shapes from cocci to rods to filamentsvarying in size from 0.

It has been shown that Acholeplasma laidlawii is capable of penetrating a 0. Acholeplasma laidlawii is known to be associated with animal-derived material, and microbiological media is often from animal sources. For now, this firm has decided to filter prepared TSB, for use in media fills, through a 0.

In the future, the firm will use sterile, irradiated TSB when it becomes available from a commercial supplier.In the U. In the last ten years media fills have, in the eyes of the regulatory bodies, developed from a reasonably good way of validating aseptic processes, through to the preferred way of validating aseptic processes, to an essential requirement of a properly validated aseptic process. It is now highly unlikely that any regulatory submission for a new aseptically filled sterile pharmaceutical product would be acceptable without supportive media fill data.

It is also unlikely that a manufacturer of an existing aseptically filled sterile product would escape severe regulatory criticism if media fill data were unavailable. It is now well accepted in the pharmaceutical manufacturing industry that validation is an exercise intended to confirm that a process is capable of operating consistently. As far as asepsis is concerned, the consistency of the contamination control "engineering" of a process is qualified by three successive replicate media fills done on separate days.

Completion of the media fills is usually the factor that dictates the time of handover of the process for routine usage. New aseptic processes require validation by media fill. Any process irrespective of the equipment being old or new beginning in a new clean room requires media fills as part of validation. A new filling machine in an established clean room requires validation media fills. The trickier decisions arise over container sizes. It is quite probable that a range of container sizes may be filled on the same filling line.

The question then arises over the necessity to perform media fills on all sizes, and in validation in particular, whether it is necessary to replicate each size through three media fills. The glib answer is that media fills should only be necessary for the container size that takes longest to fill and has the widest neck diameter. This combination presents the greatest potential for contamination and therefore addresses the contamination potential for all smaller sizes. However, this is not necessarily true.

Wide-neck containers may be more stable than narrow-neck containers. Therefore the wide-neck filling process may be arguably less susceptible to contamination because there are fewer personnel intrusions necessary for rectifying fallen containers. Glass moulders often use a common neck or flange mold for different capacity vials; it would be usual for vials with capacities from 10 ml to ml to have identical necks and flanges.

There is probably no sensible way of rationalizing media fills to fewer than two container sizes on a multicontainer filling line. The decision over what and how many sizes to include in a media fill validation protocol is judgmental.