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Preven(on
in
the
Manufacture
of
Crop
Protec(on
Products
June 2014
Contamina2on
Preven2on
What
are
the
CropLife
Requirements?
Ensure
that
No
extraneous
ac2ve
ingredients
are
present
in
products
In
compliance
with
legal
requirements
and
local
legisla2on
External
Manufacturers
are
provided
adequate
informa2on
to
adhere
to
the
requirements
June 2014
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The
situa2on.
June 2014
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The situa2on.
June 2014
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The situa2on.
2000
ppm
vs
1000
ppm
June 2014
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The situa2on.
A
high
mel2ng
point
ac2ve
ingredient
required
the
use
of
a
heat
exchanger
during
the
formula2on.
Cleaning
did
not
include
the
heat
exchanger
as
it
was
not
needed
for
the
next
formula2on.
Five
weeks
later,
the
next
formula2on
requiring
the
heat
exchanger
became
contaminated
because
the
heat
exchanger
had
not
been
cleaned.
The
batch
had
to
be
discarded
June 2014
Dont
bypass
equipment
during
cleaning
steps
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The situa2on.
Is
the
default
limit
always
low
enough?
June 2014
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The situa2on.
An
operator
wrongly
connected
and
transferred
a
formula2on
(vessel
should
be
locked
if
not
in
use)
The
operator
did
not
tell
anyone
of
the
error
Thousands
of
liters
of
product
had
to
be
recalled
and
destroyed
The
wrong
formula2on
transferred
was
extremely
toxic
to
benecial
insects
June 2014
Contamina2on
Preven2on
Example
Of
An
Actual
Incident
The situa2on.
During
the
packaging
of
a
corn
herbicide,
an
operator
no2ced
an
unusual
color
and
packing
was
stopped
Material
resampled
and
an
unexpected
ac2ve
ingredient
detected
The
packaging
line
shared
a
nitrogen
purge
with
another
produc2on
line
The
purge
was
open
when
a
transfer
occurred
at
the
other
line
resul2ng
in
material
being
siphoned
into
the
corn
herbicide
If
it
doesnt
look
normal
stop
June 2014
10
Contamina2on
Preven2on
What
is
Needed?
Documented
Risk
Assessments
June
2014
Clear labelling
Cleaning
procedures
and
analy2cal
methods
11
Contamina2on
Preven2on
What
is
Needed?
Addi8onal
Requirements
Dene
Residual
Cleaning
Limits
Promptness
in
Clean
out
Rellable
container
maintenance
June
2014
1,000
1,000
1,000
67
100
1,000
1,000
1.0
1,000
1,000
1,000
1,000
1,000
100
100
1,000
NA
1.0
1,000
1,000
1,000
1,000
1,000
67
100
500
NA
1.0
1,000
1,000
1,000
1,000
1,000
33
100
1,000
NA
1.0
1,000
1,000
NA
1,000
1,000
100
100
1,000
1,000
1.0
1,000
1,000
NA
1,000
1,000
100
100
1,000
1,000
1.0
1,000
1,000
NA
1,000
1,000
100
100
500
1,000
1.0
1,000
1,000
NA
1,000
1,000
100
100
1,000
1,000
1.0
1,000
1,000
NA
1,000
1,000
100
100
1,000
1,000
1.0
1,000
1,000
1,000
1,000
1,000
119
NA
417
833
20
1,000
1,000
1,000
1,000
1,000
167
NA
833
1,000
20
1,000
1,000
1,000
1,000
1,000
167
NA
833
1,000
20
1,000
1,000
1,000
1,000
1,000
250
NA
1,000
1,000
20
1,000
1,000
1,000
1,000
1,000
250
NA
1,000
1,000
20
1,000
1,000
1,000
1,000
1,000
250
NA
1,000
1,000
20
1,000
1,000
1,000
1,000
1,000
250
NA
1,000
1,000
20
1,000
1,000
1,000
1,000
1,000
250
NA
1,000
1,000
20
1,000
1,000
1,000
1,000
1,000
250
NA
1,000
1,000
20
1,000
1,000
1,000
1,000
1,000
50
100
1,000
1,000
1.0
1,000
1,000
1,000
1,000
1,000
50
100
1,000
1,000
1.0
1,000
1,000
1,000
1,000
1,000
50
100
1,000
1,000
1.0
1,000
1,000
1,000
1,000
1,000
100
100
1,000
1,000
1.0
1,000
1,000
1,000
1,000
1,000
100
100
1,000
1,000
1.0
1,000
1,000
Portable
equipment
must
be
dedicated
Contamina2on
Preven2on
What
Should
Management
Do?
Good Housekeeping
Ensure
Training
and
Awareness
Conden2ally
of
Exchanged
Informa2on
Resource Availability
Applica2on
of
Requirements
and
Best
Prac2ces
June 2014
13
The
Details
The
following
slides
outline
the
specic
how
with
each
element
of
contamina(on
preven(on.
June 2014
14
External
Manufacturing
Informa2on
Exchange
The
External
Manufacturer
must
supply
the
succeeding
client
the
following:
All
crop
protec2on
ac2ve
ingredients
handled
at
the
site
(contact
person
if
secrecy
agreements
in
place)
Produc2on
unit
congura2on,
conrmed
cleaning
out
documenta2on
The
physical
layout
that
impacts
Contamina2on
Preven2on
Parallel
opera2ons
(focusing
on
the
separa2on
elements)
Loca2on
of
the
facility
(GPS
coordinates)
List
of
Ac2ves
Layout of Unit
Loca2on of Facility
Metosulam
Mesotrione
S-Metolachlor
Haloxyfop-p-methyl
June
2014
15
External
Manufacturing
Informa2on
Exchange
Requestor
Provider
External
Manufacturing
Succeeding
Client
Preceding
Client
Analy2cal
standards*
Analy2cal
methods*
Cleaning
methods*
Succeeding Client
Cleaning limits
16
Minimum
Requirements
for
External
Manufacturers
Client
is
responsible
for
June 2014
17
Minimum
Requirements
for
External
Manufacturers
The
following
should
be
incorporated
into
the
agreement/contract
between
the
client
and
external
manufacturer.
June 2014
18
Procurement/Purchasing
of
Ac2ve
Ingredients
If
Ac2ve
Ingredients
are
purchased,
the
following
are
minimum
items
to
be
included
in
a
supply
contract:
v Any
non-listed
compound
in
the
supplied
product
must
be
<
1000
ppm
or
below,
in
case
of
biological
ac<vity
at
lower
levels
if
there
are
adverse
eects
on
crops,
users
and/or
environment.
OR
v Informa2on
exchange
for
other
ac2ve
ingredients
manufactured
on
the
same
produc2on
and
packaging
line,
and
a
cleaning
matrix
in
place
(provided
by
customer)
and
cleaning
limits
will
be
achieved
(by
supplier).
19
June 2014
20
Herbicides
Non-herbicides
e.g.
herbicides,
defoliants,
and
desiccants
June 2014
21
Cleaning
Capability
Two
cri2cal
elements
which
must
always
be
evaluated
1.
Design
of
the
produc(on
unit
(look
for
dead
spaces)
2.
Cleaning
procedures
Cleaning
Levels
June 2014
Cleaning
Methods
Analy(cal
Documenta(on
22
June 2014
23
Recommended
to
appoint
a
specialist
to
calculate
cleaning
levels
June 2014
24
June 2014
25
Cleaning
Level
[
ppm]
=106 /
June 2014
26
Herbicide
A
Metosulam
Herbicide
B
Mesotrione
S-Metolachlor
Haloxyfop-p-methyl
Crop
April 2014
Herbicide C
NOEL [g AI / ha]
Corn (Maize)
50
(registered
crop)
500
(registered
crop)
2500
(registered
crop)
0.015
Oilseed Rape
0.005
1.70
800
>
200
(registered
crop)
Sugar beet
0.005
1.70
500
>
200
(registered
crop)
Tomatoes
0.2
0.40
>
200
(registered
crop)
Turf
(golf
courses)
25
(registered
crop)
280
1500
0.01
27
Cleaning Matrix
Preceding Herbicide
AI Preceding Herbicide
Herbicide A
Metosulam
Mesotrione
Herbicide
B
S-Metolachlor
Herbicide
C
Haloxyfop-p-methyl
Herbicide A
Metosulam
Herbicide B
Mesotrione
S-Metolachlor
Herbicide C
Haloxyfop-p-methyl
Herbicide
B
Herbicide
C
Treated
Crop
Maize
(Corn),
Turf
Maize
(Corn)
OSR,
S-beet,
tomato
Max.
Applica8on
Rate
[g
Formulated
Product/ha]
200
5000
500
Biology
Based
ARILs
(ppm)
5000
N/A
5.0
<
1000
700000
400
<
1000
N/A
15000000
5000
<
1000
<
1000
25
1
N/A
US
EPA
PRN
96-8
based
ARILs
(ppm)
100
N/A
20
5
100
100
N/A
250
250
100
20
N/A
25
1
[1] If the value of the ARIL is higher than the legally accepted one, this value has to default to < 1000 ppm.
June 2014
28
Produc2on
Sequencing
There
may
be
preferred
op2ons
in
sequencing
produc2on,
avoid
low
cleaning
limits.
Op2mum
sequencing
can
reduce
cleaning
2me
and
waste.
void
a
d
to
e
c
n
e
sequ vels
y
l
r
e
e
Prop leaning
l
c
low
Sequence
Herbicide A
Metosulam
Sequence
Herbicide A
Metosulam
Sequence
3
Herbicide
B
<
1000
Metolachlor
400
<
1000
Herbicide
C
5
Haloxyfop-p-
25
methyl
Herbicide
A
Metosulam
Herbicide
C
Haloxyfop-p-
Mesotrione
+
S-
Metolachlor
Herbicide
B
< 1000
25
methyl
Herbicide
B
methyl
Herbicide
C
Haloxyfop-p-
Mesotrione + S-
Mesotrione
+
S-
Metolachlor
Herbicide
A
Metosulam
< 1000
Herbicide A
< 1000
Metosulam
< 1000
Herbicide A
< 1000
Metosulam
Sequence 2
Herbicide
A
Metosulam
Herbicide
A
Metosulam
Herbicide
B
20
Metolachlor
Haloxyfop-p-
methyl
June 2014
250
Herbicide
C
5
Haloxyfop-p-
25
Herbicide
A
Metosulam
Herbicide
C
Haloxyfop-p-
Mesotrione
+
S-
Metolachlor
Herbicide
B
20
25
methyl
Herbicide
B
methyl
Herbicide
C
Sequence
3
Mesotrione + S-
100
Mesotrione
+
S-
Metolachlor
Herbicide
A
Metosulam
100
Herbicide A
250
Metosulam
100
Herbicide A
250
Metosulam
29
Honey
bee
LD50
values
are
typically
available
for
all
ac2ve
ingredients.
An
equa2on
for
calcula2ng
Insec2cide
Cleaning
Levels
can
be
found
in
the
booklet
in
more
detail
(see
chapter
6.3).
June
2014
30
June 2014
31
Manufacturing
Prac2ces
Iden2ca2on
of
Incoming
Goods
A
few
steps
need
to
be
completed
when
receiving
goods
into
a
facility
Check
Check
Verify
June 2014
32
June 2014
33
Staging
Material(s)
Store
herbicide
ac2ves
and
associated
raw
materials
separately
from
non-herbicide
ac2ves
and
associated
raw
materials
June 2014
34
Shared
Equipment
Create
a
procedure
for
using
shared
equipment,
iden2fying
steps
to
take
when
transferring
from
one
area
to
another.
June 2014
35
Shared
Equipment
Direct
contact
No
Direct
Contact
June 2014
36
Tools
Sharing
tools
is
permiZed
but
check
to
be
sure
they
are
clean
(no
residue
present)
June 2014
37
June 2014
38
June 2014
39
Name
of
material
Product
code
Batch
number
Produc2on
date
Quan2ty
June 2014
40
Storage
of
Materials
Raw
materials
for
herbicide
and
non
herbicide
opera2ons
may
be
stored
together
if:
The
outside
of
the
package
is
clean
Herbicide
and
non-herbicide
ac2ve
ingredients
are
physically
separated
Non-herbicide
inert
raw
materials
are
physically
separated
from
herbicide
ac2ve
ingredients
Separa2ons
clearly
marked
Clear
labeling
in
place
Par2ally
used
materials
must
be
returned
to
appropriate
storage
areas
and
wrapped
June 2014
41
Storage
Tanks
Feeding
from
a
common
inert
raw
material
tank
can
be
a
risk
2
layers
of
protec2on
should
be
part
of
the
design:
Mul2ple
isola2on
valves
in
series
Blanked/blind
anges
Isola2on
valve
and
blanked/blind
ange
Isola2on
valve
with
a
physical
break
June 2014
42
If
storing
rework,
quaran2ne,
segregate
and
only
store
the
same
product
on
the
pallet.
If
seal
on
returned
material
is
not
intact,
discard.
If
intact,
conduct
risk
assessment.
Product
release
samples
must
not
be
recycled.
43
O-spec
Recycling
cleaning
medium,
rst
includes
a
risk/benet
discussion.
Material
Name:
Product
Code:
Batch
Number:
Produc2on
Date:
Quan2ty:
Good
Stu
XYM985
AC151406
03-14-14
50.2
kg
To
avoid
mix-ups,
label
control
needs
to
be
in
place
June 2014
45
Traceability
Traceability
must
be
in
place
for
produc2on,
lling
and
packaging
opera2ons.
Items
to
consider:
June 2014
46
Modica2ons
When
a
produc2on
unit
is
modied
or
updated,
ensure
that
Yes or No
Verify
cleaning
procedures
aXer
change
Before
rst
use,
ensure
cleanliness
A
Management
of
Change
procedure
is
in
place.
June 2014
47
Self-Assessment
Plan
Act
June 2014
Do
Check
48
Produc2on
Scheduling
Items
to
consider
when
scheduling
produc2on:
Using
dedicated
lines
Moving
low
rate
and/or
highly
ac2ve
herbicides
together
with
comparable
products
Consolida2ng
highly
ac2ve
products
in
one
unit
Low
rate
refers
to
herbicides
with
an
applica<on
rate
of
to
560
g
AI/ha.
Highly
ac<ve
refers
to
herbicides
with
an
applica<on
rate
of
<
50
g
AI/ha
June 2014
49
Cleaning
Procedures
WriZen
procedures
for
cleaning
must
detail:
Cleaning
medium
used
The
order
in
which
parts/lines
are
cleaned
How
the
cleaning
medium
is
applied
Flush
quan2ty
Dismantling
and
manual
cleaning
Flush
sample
loca2ons
Internal
equipment
drying
Instruc2ons
for
handling
cleaning
medium
(dispose/recycle)
There are specic guidelines for cleaning liquid versus solid produc2on units.
June 2014
50
Visual
Inspec2on
Visual
inspec2on
is
a
key
step
in
cleaning
If
residue
is
present,
repeat
cleaning
step
as
appropriate.
Use
tools,
like
mirrors,
to
inspect
for
dead
spaces.
June 2014
51
Wet
Cleaning
Depending
on
the
design,
wet
cleaning
is
recommended
for
liquid
products
and
can
also
be
applied
in
solid
products
cleanout.
June 2014
52
Dry
Cleaning
A
solid
ush
uses
an
inert
material.
AXer
solid
ushing:
Deposits
are
removed
by
opening
or
dismantling
equipment.
Brushing
or
vacuuming
interiors
June 2014
53
Cleanout
Capability
Cleanout
capability
is
demonstrated
when
the
cleaning
level
is
consistently
achieved
using
the
cleaning
procedure.
Capability
is
demonstrated
through:
Deni2on
of
cri2cal
parameters
(design,
process
condi2ons)
Selec2on
of
low
level
or
dicult
cleanouts
Adherence
to
procedures
Analyses
of
mul2ple
cycles
of
residue
material
Analysis
of
the
succeeding
product
for
RI
of
previous
product
If
any
of
the
cri2cal
parameters
change,
re-evalua2on
is
needed.
Training
of
all
personnel
involved
is
key
to
ensure
eec2ve
repeatable
cleanouts.
June 2014
54
Cleaning
Medium
Recycling
used
cleaning
medium
should
be
based
on
a
risk
assessment.
Re-use
savings
Ecological
June 2014
Labeling
errors
Storage
stability
55
June 2014
56
Sampling
Determine
sampling
loca2ons...
Formula2on
vessels
Packaging line
Last rinsate
June 2014
57
Analy2cal
Methods
Analy2cal
methods
need
to
be
developed
for
the
determina2on
of
residual
impuri2es.
Valida2on
of
methods
should
include:
Specicity
Recovery
Repeatability
Linearity
Contamina(on
can
occur
in
the
lab;
systems
should
be
in
place
to
use
clean
glassware,
vials,
etc.
Understand
the
cleaning
levels
and
choose
the
appropriate
analy2cal
approach.
June 2014
58
Contamina2on
Preven2on
Making
it
Sustainable
Keep
all
the
Pieces
Together
June 2014
59
Disclaimer
June 2014
60