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INITIATED BY:
CHEMIST
Q.A.
REVIEWED BY:
DEGINATION NAME SIGNATURE DATE
MANAGER
(PRODUCTION)
MANAGER
(ENGINEERING)
MANAGER
(QUALITY CONTROL)
HEAD
(QUALITY ASSURANCE)
SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 5 OF 20
2.0 INTRODUCTION:
This document applies to the Moist Heat Sterilizer (Autoclave) Machine Specified by M/s SGS
PHARMACEUTICALS PVT.LIMITED, Roorkee, Haridwar-(U.K.)-247667-INDIA.
The system is designed considering as the basis for specification parameters with allowable
parameters at user end with suitable Design Limits.
3.0 OBJECTIVE:
The process of MHS is evaluated on basis of Different Cycle Test design to demonstrate that
the sterilization and associated control procedure can reproducibly deliver a sterile product.
To confirm/demonstrate the efficiency of sterilization process, which is capable of killing the
Micro-organisms & Pyrogene present in the article to sterilized in the Moist Heat Sterilizer.
To establish documented evidence that the Equipment is capable of performing as per specified
acceptance criteria and is adequate to provide the assurance for which the process is in intended
The performance shall be measured and evaluated by-
* Vacuum leak Rate Test (3 trials)
*Bowie Dick Test (3 Trials on different days)
* Heat Distribution Study in different three cyle.
* Heat Penetration Study
* Biological challenge testing for standard and reduced cycle loads
The Heat distribution & Heat penetration studies shall be conducted to check the performance of
sterilization cycle.
The validation protocol Cum-Report is designed to establish & provided the documentary
evidence, to assure that the Moist Heat Sterilizer, Make Lance Engineering is suitable for
Sterilizing different load. In addition, this validation protocol Cum-Report is intended to assure
the sterility of the items, when the established Standard Operating Procedure to maintain reliability
and repeatability.
To confirm the suitability of the Standard Operating Procedure for all routine activities
associated with the system.
4.0 SCOPE
The Performance Qualification is an essential part of the qualification mechanism. The scope of this
protocol Cum-Report is to provide the complete documentary evidence for the performance
qualification of the Moist Heat Sterilizer.
The protocol Cum-Reports cover all aspects of Performance Qualification for the Moist Heat Sterilizer
Serving M/s SGS PHARMACEUTICALS PVT.LIMITED , Roorkee Distt.haridwar ( U.K.) -247667 .
This protocol Cum-Report will define the method and documentation used to quality the Moist Heat
Sterilizer for Performance Qualification.
To ensure the Moist Heat Sterilizer meet the cGMP requirement.
SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 6 OF 20
To confirm the appropriateness of critical parameters of the Moist Heat Sterilizer components.
To validate the system and check its performance.
5.0 RESPONSIBILITY:
The Validation Group comprising of a representative from each of the following Department shall
be responsible for the overall compliance of this protocol Cum-Report.
DEPARTMENT RESPONSIBILITIES
Preparation, Review, Approvel and Compilation of the Qualification Protocol
Cum-Report for Correctness, Completeness and Technical Excellence.
QUALITY Protocol Cum-Report Training
ASSURANCE Co-ordination with Quality Control, Production and Engineering to carryout
Qualification Activities.
Monitoring of Qualification Activity.
* EQUIPMENT USE:
……………………………………………………………………………………………
8.0 FREQUENCY OF QUALIFICATION:-
Yearly as per Master Validation Plan.
After any major breakdown or modification.
» Acceptance criteria :
● The rate of vacuum drop at the end of 10 min not more than 30 m bar or 1.3 m bar /min .
SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 11 OF 20
» Acceptance criteria :
● Bowie dick test pack should be uniform dark black color pattern indicates .
14.4 HEAT DISTRIBUTION STUDY
HEAT DISTRIBUTION STUDY IN EMPTY CHAMBER
» Objective
Physical qualification of the production sterilization cycle to demonstrate that heat distribution with in
the empty chamber is consistent .
The Sterilizer is capable of at training a temperature and pressure of 121 ºC and 1.5 kg/cm2 or 15 lbs
during the sterilization hold period.
» Procedure
Fit the 16 thermocouple probes ( S1,S2,S3…….S16) through the validation port in the autoclave door
and check the connection to the autoclave data recorder the position each probe.probe replacement
inside the chamber shall reflect the result for determination of hot and cold point with in chamber .
» Acceptance criteria :
● Record over all time for cycle and verify that heating time is consistent .
● Leak rate test remain within specification .
Stratification within is the a chamber is acceptable. that is thermocouple probes mesure within ±2˚C
of each other.
All measured thermocouple temperature show 121˚C +3/-0˚C and do not fluctuate by more than 1˚C
During the sterilization hold phase.
At least 10 thermocouples probes remain active during the study.
Correlate autoclave temperature and pressure readings during the sterilization hold time, against
saturated steam tables and record the result.
Verify that the accumulated heat loads for each probe as indicated by F0 are consistant.
FPhys=ΔtΣ10 (T0-T ref) /Z
Where
Δt = 1 minute
T
0 = Thermocouple temperature (˚C)
T
ref = 121˚C
SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 12 OF 20
Physical qualification of the production sterilization cycle to demonstrate that heat distribution within
the loaded chamber is consistent.
The Sterilizer is capable of at training a temperature and pressure of 121 ºC and 1.5 kg/cm2 or 15 lbs
during the sterilization hold period.
» Procedure
Define the Load pattern as Loaded cycles
Load cycles 1 : 15 pairs of Sterile dress , 30 pairs of gloves .
Load cycle 2: Machine parts , one filling vessel , one filter assembly .
Load cycle 3 : Maximum 50000 rubber plugs/ 50000 flip off seals.
Fit the 16 thermocouple probes ( S1,S2,S3…….S16) through the validation port in the autoclave door
and check the connection to the autoclave data recorder the position each probe.probe replacement
inside the chamber shall reflect the result for determination of hot and cold point with in chamber .
» Acceptance criteria :
● Record over all time for cycle and verify that heating time is consistent .
● Leak rate test remain within specification .
Stratification within is the a chamber is acceptable. that is thermocouple probes mesure within ±2˚C
of each other.
All measured thermocouple temperature show 121˚C +3/-0˚C and do not fluctuate by more than 1˚C
During the sterilization hold phase.
At least 10 thermocouples probes remain active during the study.
Correlate autoclave temperature and pressure readings during the sterilization hold time, against
saturated steam tables and record the result.
Verify that the accumulated heat loads for each probe as indicated by F0 are consistant.
FPhys=ΔtΣ10 (T0-T ref) /Z
Where
Δt = 1 minute
T
0 = Thermocouple temperature (˚C)
T
ref = 121˚C
Where
Δt = 1 minute
T
0 = Thermocouple temperature (˚C)
T
ref = 121˚C
» Objective
Biological qualification of the sterilization cycle to demonstrate that the delivered lethality measured by
the actual kill of micro-organism on a biological indicator system results in PNSU ≤ 10-6.
» Procedure :
This test is run concurrently with the test of heat penetration ( i.e. temperature probes and biological
indicators placed adjacently in the same loads )
Record the position and tag of each biological indicators
Complete the sterilization cycle as heat penetration study .
Stop the heat penetration study after the first sterilization cycle has completed .
Open the door prepare and prepare the next test cycle removing by the used biological indicators and
placing a fresh biological indicators adjacent to each temperature probes .
Transfer the used BIs to the microbiology lab for incubation an testing
» Acceptance criteria :
There shall be no growth of BIs ,which have undergone the sterilization cycle .
There shall be positive growth of the controlled biological indicators ,which have not undergone the
sterilization cycle .
Bio-indictors shall comply with specification before use .Glass ampoules G.stearothermophilus ,the
biological indicators shall have :
Population > 5 x 105 G.stearothermophilus ( ATCC7953) per ampoules ,
With a D value of not less than 1.5 min and not more than 2 min.
15.0 REFERENCES:
The Principle Reference is the following:
Master Validation Plan
Schedule –M-“Good Manufacturing Practices” and Requirement of Premises, Plant and Equipment
for Pharmaceutical Product.
WHO Essential Drugs and Medicines Policy, QA of Pharmaceuticals, Vol.-2 Good Manufacturing
Practices and Inspection.
The following references are used to give addition guidance:
Code of federal regulation(CFR),title 21,Part 210 current-Good Manufacturing Practices (cGMP) in
Manufacturing,Processing,Packing,of Holding of Drugs,General.April1,1998.
Code of federal regulation (CFR), title 21,Part 211 current-Good Manufacturing Practices (cGMP) for
Finished Pharmaceuticals April1,1998.
EU Guide to Good Manufacturing Practices, Part 4, 1997.
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SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 16 OF 20
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SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 17 OF 20
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20.0 ABBREVIATIONS
CFM : Cubic Feet Meter
Pvt. : Private
Ltd. : Limited
D.M. : Demineralized
Maint. : Maintenance
QA : Quality Assurance
No. : Number
◦C : Degree Celsius
GMP : Good Manufacturing Practices
WHO : World Health Organization
CFR : Code of Federal Regulation
BIs : Biological indicaors
PNSU : Probability of a non – sterile unit
SAL : Sterility Assurance Level
SGS PHARMACEUTICALS PVT. LTD.
162/1, Puhana - Iqbalpur Road, Village: Nanhera,
Roorkee (Uttarakhand)-247667
PERFORMANCE QUALIFICATION PROTOCOL CUM REPORT
Equipment Name : MOIST HEAT STERILIZER Protocol No. : SGS/VPR/ATC/001
Equipment ID. No. : SGS/LIQ/WAV/ATC/001 Page No. : 19 OF 20
21.0 ANNEXURES:
REVIEWED BY:
MANAGER
(PRODUCTION)
MANAGER
(ENGINEERING)
MANAGER
(QUALITY CONTROL)
HEAD
(QUALITYASSURANCE)