Basic Principles of GMP Premises Part One 12

Basic Principles of GMP Premises Part One 12 Module 9 | January 2006 Slide 1 of 45 STOP

Premises Objectives 1. To review general requirements 2. To list key requirements for site choice 3. To consider specific requirements for main areas 4. To list major facilities required in a multifunction site Module 9 | January 2006 Slide 2 of 45 STOP

Premises Principle Important aspects to be kept in mind to ensure the suitability of the operations to be carried out for different dosage forms and product range: l l l Location Design Construction Adaptation Maintenance 12. 1 Module 9 | January 2006 Slide 3 of 45 STOP

Premises Location l Geography, climate, noise and economic factors l Neighbours ä What do they do? ä What impact can they have on the business? l Pollution/effluent control l Minimum risk for contamination of products and materials 12. 1, 12. 4 Module 9 | January 2006 Slide 4 of 45 STOP

Premises Principle l Premises must be located to minimize risks of crosscontamination, e. g. not located next to a malting factory with high airborne levels of yeast 12. 4 Module 9 | January 2006 Slide 5 of 45 STOP

Premises General The layout and design should aim to: l Minimize risks of errors l Permit effective cleaning l Permit effective maintenance l Avoid cross-contamination, build-up of dirt and dust l Avoid any adverse effect on the quality of products 12. 2 Module 9 | January 2006 Slide 6 of 45 STOP

Premises Design Principles Keep in mind: l Material flow l People flow l Process flow Ensure logical flow 12. 10 Module 9 | January 2006 Slide 7 of 45 STOP

Premises Example of Materials and People Flow Arrival of goods Entrance for visitors Entrance for Workers Shipment of goods Material Flow People Flow Zone: Clean Zone: Packaging Zone: Controlled Module 9 | January 2006 Slide 8 of 45 STOP

Premises Design l Suitable design and construction to facilitate good sanitation l Cleaning and disinfecting according to detailed written procedures – records maintained l Maximum protection against entry of insects, birds and animals l Procedure for rodent and pest control 12. 5, 12. 7, 12. 9 Module 9 | January 2006 Slide 9 of 45 STOP

Premises Construction l Suitable materials l Electrical supply l Suitable lighting (especially for visual on-line checks) l Temperature and relative humidity control l Appropriate and effective ventilation These may affect products during manufacture or storage as well as functioning of equipment 12. 8, 12. 32 Module 9 | January 2006 Slide 10 of 45 STOP

Basic Principles of GMP l The temperature and relative humidity should be controlled, monitored in accordance with an SOP, and the results recorded. The limits should be appropriate according to the materials stored and product processed Module 9 | January 2006 Slide 11 of 45 STOP

Premises Construction l Dust generating operations ä e. g. during sampling, weighing, mixing, packing of powders, etc. ) l Measures should be taken to prevent cross-contamination l Measures to facilitate cleaning 12. 3 Module 9 | January 2006 Slide 12 of 45 STOP

Basic Principles of GMP Design of areas for weighing of materials l Proper air supply l Dust control measures (including extraction of dust and air) l Easily cleanable surfaces l No areas for dust accumulation l Protection of material, product and operator Module 9 | January 2006 Slide 13 of 45 STOP

Premises Maintenance l Careful maintenance done l Repairs and maintenance should not present any hazard to the quality of the products 12. 6 Module 9 | January 2006 Slide 14 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 15 of 45 STOP

Premises Specific areas Review some recommendations for specific areas in the following slides (Part 2): l Ancillary areas l Storage areas l Weighing areas l Production areas l Quality control areas 12. 11 – 12. 36 Module 9 | January 2006 Slide 16 of 45 STOP

Basic Principles of GMP Premises Part two 12 Module 9 | January 2006 Slide 17 of 45 STOP

Premises Ancillary Areas l Rest and refreshment rooms separate from manufacturing and quality control areas l Changing, washing and toilet areas accessible and appropriate numbers l Maintenance workshops separated from production - if not possible – tools in reserved areas l Animal houses well isolated – separate air handling and entrance 12. 11 – 12. 14 Module 9 | January 2006 Slide 18 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 19 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 20 of 45 STOP

Basic Principles of GMP l Separate receiving and dispatch bays ä Materials and products protected from weather l Area to clean incoming materials provided Module 9 | January 2006 Slide 21 of 45 STOP

Basic Principles of GMP Cleaning of incoming containers l Cleaning with a cloth, or duster l Cleaning by using a vacuum cleaner l Use of air curtains and air tunnels Module 9 | January 2006 Slide 22 of 45 STOP

Premises Storage areas - 1 l Storage areas of sufficient capacity l Orderly storage of categories of materials and products l Separate and segregated areas: starting materials, packaging materials, intermediates, bulk, finished products, quarantined, released, rejected, returned and recalled products and materials 12. 15, 12. 16 Module 9 | January 2006 Slide 23 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 24 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 25 of 45 STOP

Premises Storage areas - 2 l Appropriate temperature and relative humidity conditions within defined limits ä Provided, controlled, monitored and recorded l Good storage conditions: clean, dry and appropriate lights 12. 16, 12. 17 Module 9 | January 2006 Slide 26 of 45 STOP

Premises Storage areas - 3 l Quarantine area: clearly marked and access restricted l A separate sampling area is the norm: no risk for contamination or cross-contamination l Segregated areas for rejected, recalled and returned materials and products l Safe and secure areas for highly active, radioactive materials, narcotics and other materials (risk of abuse, fire, explosion) 12. 18 – 12. 20, 12. 22 Module 9 | January 2006 Slide 27 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 28 of 45 STOP

Premises Storage areas – 4 Printed packaging materials l Critical to ensure compliance with correct labelling of products l Special attention to sampling l Special attention to safe and secure storage l Ensure compliance with specifications, prevent mix-ups 12. 21 Module 9 | January 2006 Slide 29 of 45 STOP

Premises Weighing areas l Weighing operations – in separated areas l Appropriate design (see also training material on HVAC) l Provision for dust control l Smooth, impervious, durable, easy-to-clean finishes l Cleaning procedures and records l Documentation, e. g. SOPs, logs and records 12. 23 Module 9 | January 2006 Slide 30 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 31 of 45 STOP

Premises Production areas - 1 Minimize risk of cross-contamination: l Dedicated and self-contained facilities for some products such as highly sensitizing materials (e. g. penicillins) or biological preparations (e. g. live microorganisms) l Separate facilities for other products such as some antibiotics, hormones, cytotoxic substances l Non-pharmaceuticals normally not in the same facility, e. g. pesticides, herbicides 12. 24 Module 9 | January 2006 Slide 32 of 45 STOP

Premises Production areas -2 l Layout in accordance with sequence of production l Appropriate cleanliness level l Adequate work and in-process storage space l Orderly and logical positioning of equipment ä minimizes risk of contamination, mix-ups and missing production steps l Specially designed areas for packaging l Layout to avoid mix-ups and cross-contamination 12. 32, 12. 26, 12. 31 Module 9 | January 2006 Slide 33 of 45 STOP

Premises Production areas - 3 l Starting and packaging materials, intermediates and bulk exposed to environment: ä Interior surfaces (walls, floors, ceilings) – smooth, free from cracks and open joints ä No shedding of particles ä Easy and effective cleaning permitted l Disinfection if needed 12. 27 Module 9 | January 2006 Slide 34 of 45 STOP

Premises Production areas - 4 l Design of pipework, light fittings, and ventilation points – no recesses that are difficult to clean l Access for maintenance from outside production areas l Drains of adequate size, and equipped to prevent back-flow l Open channels avoided 12. 28, 12. 29 Module 9 | January 2006 Slide 35 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 36 of 45 STOP

Premises Production areas - 5 l Effective ventilation with air control facilities l Including filtration of air to a sufficient level to prevent contamination and cross-contamination – also external environment l Control of temperature and relative humidity where necessary l Regular monitoring of conditions during production and nonproduction periods 12. 30 Module 9 | January 2006 Slide 37 of 45 STOP

Premises Quality Control areas - 1 l QC laboratories should be separate from production areas l Separate areas for biological, microbiological and radioisotope methods l Suitable design with sufficient space to avoid mix-ups and cross-contamination l Suitable space for storage samples, reference standards, solvents, reagents and records 12. 33, 12. 34 Module 9 | January 2006 Slide 41 of 45 STOP

Basic Principles of GMP Module 9 | January 2006 Slide 42 of 45 STOP

Premises Quality Control areas - 2 l Suitable construction materials l Prevention of fumes l Ventilation l Separate air supply (production and QC) l Separate rooms for some instruments to protect them from interference (e. g. electrical, vibration, moisture, etc. ) See supplementary training on QC laboratories Module 9 | January 2006 Slide 43 of 45 STOP 12. 35, 12. 36

Premises Group Session - Option 1 l A company wishes to manufacture simple, non-sterile medicines. It has engaged a consultant to draw up some building plans l Comment on the building plans “faxed” through to your group l Comment on the people flow, the process flow and the material flow Module 9 | January 2006 Slide 44 of 45 STOP

Premises Group Session - Option 2 l Consider a multifunction factory producing sterile and nonsterile products: ä What GMP facilities would you expect to find in this factory? ä What would you look for in the quality of those facilities and what weaknesses might you find? ä How can companies overcome those weaknesses? Module 9 | January 2006 Slide 45 of 45 STOP