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USP <1115> Bioburden Control of Non‐sterile Drug Substances and Products: Intent ImplementationProducts: Intent, Implementation
and ImpactTony Cundell, Ph. D.
Consulting MicrobiologistConsulting MicrobiologistScarsdale, NY
August 4, 2014 IVT Microbiology Week 1
DisclosuresDisclosures
• The opinions expressed in this presentationThe opinions expressed in this presentation are solely mine and not those of my former employer Merck & Co the USP Microbiologyemployer Merck & Co, the USP Microbiology Committee of Experts or my current consulting clientsconsulting clients.
August 4, 2014 IVT Microbiology Week 2
IVT Microbiology WeekIVT Microbiology Week
• The speaker wish to thank IVT program managerThe speaker wish to thank IVT program manager Curry Wilson, conference chair Karen Ginsburg, and event coordinator Kelly Carr for organizing this outstanding conference.
• Congratulations.
August 4, 2014 IVT Microbiology Week 3
Presentation Outline• The intention of the USP Microbiology Committee of
Experts• Implementation of the USP Chapter• Implementation of the USP Chapter• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non‐sterile drug
products• Content of the USP Chapter <1115>• Risk hierarchy by dosage formRisk hierarchy by dosage form• Factors increasing microbial contamination risk• Drug substances• Pharmaceutical excipients• Drug Products• Role of ManufacturingRole of Manufacturing
August 4, 2014 IVT Microbiology Week 4
What is the USP?What is the USP?
• The U.S. Pharmacopeial Convention Inc. is an pindependent standards organization, founded in 1820, empowered by the U.S. Federal Food, Drug, and Cosmetic (FD&C) Act as the official drugand Cosmetic (FD&C) Act as the official drug standard‐setting organization in the U.S. for drug products. p
• The Pharmacopeial Convention publishes and maintains the United States Pharmacopoeia (USP), N ti l F l (NF) d USP R fNational Formulary (NF), and USP Reference Standards and sets the quality standards for both drug products and pharmaceutical ingredients. g p p g
August 4, 2014 IVT Microbiology Week 5
U.S. PharmacopeiaU.S. Pharmacopeia
• Hard Copy • Electronic CopyHard Copy Electronic Copy• May be download from the USP website: www.usp.org/usp‐nf/offical‐text
August 4, 2014 IVT Microbiology Week 6
USP Intention• The new USP Informational Chapter <1115> Bioburden Control of Non‐sterile Drug Substances and Products was published in the 2nd Supplement to USP37‐NF32 July 2014. What was the intent of the USP in publishing this chapter?USP in publishing this chapter?
• In the absence of regulatory guidance, the USP has provided a pragmatic scientific approach to theprovided a pragmatic scientific approach to the management of the microbial bioburden in non‐sterile drug products in keeping with patient risk and g p p g pcontamination control objectives based on risk management principles.
August 4, 2014 IVT Microbiology Week 7
USP IntentionUSP Intention
• The chapter contains information on microbialThe chapter contains information on microbial control considerations in product development, routine manufacturing, equipment design and use, microbial assessment of the non‐sterile manufacturing environment, active measures for i bi l t l d th ll t fmicrobial control, and the overall management of a
microbiological control program.• Note: It is an informational chapter and not an• Note: It is an informational chapter and not an enforceable compliance document.
August 4, 2014 IVT Microbiology Week 8
Presentation OutlinePresentation Outline• The intention of the USP Microbiology Committee of
Experts• Implementation of the USP chapter• Expected impact of the new USP chapter <1115>Expected impact of the new USP chapter 1115• Extent of microbial contamination of non‐sterile drug
products• Content of the USP Chapter <1115>• Content of the USP Chapter <1115>• Risk hierarchy by dosage form• Factors increasing microbial contamination risk• Drug substances• Pharmaceutical excipients• Role of ManufacturingRole of Manufacturing
August 4, 2014 IVT Microbiology Week 9
Industry ImplementationIndustry Implementation
• How should drug substance and drug productHow should drug substance and drug product manufacturers react to the publication of this chapter?
• I would hope that they should adopt a more risk‐based approach to bioburden control in non‐sterile drug development and manufacturing based on an understanding of what determines the presence of microorganisms in their manufacturing facilities andmicroorganisms in their manufacturing facilities and their persistence or proliferation in their drug products.products.
August 4, 2014 IVT Microbiology Week 10
Expert OpinionExpert Opinion
• David Hussong, FDA CDER Microbiology Director,David Hussong, FDA CDER Microbiology Director, stated: “For the microbiologist, this (quality initiatives) emphasizes the importance of process knowledge to replace reliance on testing samples of finished product. Avoiding microbiological d lt ti i ld li bl i di t fadulteration yields a more reliable indicator of quality, which agrees with the assertion that quality cannot be tested into the product ”cannot be tested into the product.
August 4, 2014 IVT Microbiology Week 11
Industry ImplementationIndustry Implementation
• Manufacturers should appreciate that whetherManufacturers should appreciate that whether microorganisms found in a non‐sterile product will be objectionable in that product depends their number and species, the product attributes, dosing regimen, route of administration, and targeted
ti t l tipatient population. • Any environmental monitoring program would be risk based in terms of sample selection andrisk‐based in terms of sample selection and frequency and would be used to confirm microbial control and would not be linked to product release.control and would not be linked to product release.
August 4, 2014 IVT Microbiology Week 12
Presentation Overview• The intention of the USP Microbiology Committee of Experts• Implementation of the USP Chapter• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non‐sterile drug
productsproducts• Content of the USP Chapter <1115>• Risk hierarchy by dosage formRisk hierarchy by dosage form• Factors increasing microbial contamination risk• Drug substances• Pharmaceutical excipients• Drug Products• Role of ManufacturingAugust 4, 2014 IVT Microbiology Week 13
Industry ImpactIndustry Impact
• What is the expected impact of the USP chapter?at s t e e pected pact o t e US c apte• The expectation is there would be improved and cost‐
effective bioburden controls for non‐sterile drug products to a level consistent with patient safety.
• This may reduce product recalls for microbial t i ticontamination.
• Manufacturers will be able to benchmark their bioburden control programs against thebioburden control programs against the recommendations within the chapter and adjust their programs accordingly.
August 4, 2014 IVT Microbiology Week 14
Presentation OutlinePresentation Outline• The intention of the USP Microbiology Committee of Experts
• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non sterile drug• Extent of microbial contamination of non‐sterile drug products
• Content of the USP Chapter <1115>• Risk hierarchy by dosage form• Factors increasing microbial contamination risk• Drug substances• Drug substances• Pharmaceutical excipients• Role of Manufacturingg
August 4, 2014 IVT Microbiology Week 15
Microbial ContaminationMicrobial Contamination
• The contamination of marketed products withThe contamination of marketed products with objectionable microorganisms continues to be an infrequent but chronic problem for our industry.
• There are the order of 20 U.S. recalls on non‐sterile products annually for microbial contamination.
August 4, 2014 IVT Microbiology Week 16
What are Objectionable Microorganisms?What are Objectionable Microorganisms?
They are defined by specific dosage forms. They include specified microorganisms, frank pathogens and opportunistic pathogens that are known from the clinical literature to cause known from the clinical literature to causeinfection in the recipient via the route of administration or microorganisms that grow in the product overcoming the preservative systemp g p y
Also, they may include organisms associated with major recalls for microbial contamination
If these microorganisms are present in the drug If these microorganisms are present in the drug product below the microbial limit, the batch would be rejected.
August 4, 2014 IVT Microbiology Week 17
U.S. Congressional HearingsU.S. Congressional Hearings
August 4, 2014 IVT Microbiology Week 18
U.S. Recalls
• A recent U.S. survey reported 144 recalls composed of non‐sterile branded pharmaceutical drugof non sterile branded pharmaceutical drug products (5%), over‐the‐counter drug products (42%), cosmetics (31%), medical devices (14%) and ( ) ( ) ( )dietary supplements (8% of the total recalls) for microbiologically‐related issues for the 7‐year
f h hperiod from 2004 through 2011 • The survey highlighted that the majority of these
ll (72%) i t d ith bj ti blrecalls (72%) were associated with objectionable microorganisms and not for exceeding the microbial enumeration limits (Sutton and Jimenez 2012)enumeration limits (Sutton and Jimenez, 2012).
August 4, 2014 IVT Microbiology Week 19
Microorganisms ImplicatedMicroorganisms Implicated
• The most frequently cited microorganisms in theThe most frequently cited microorganisms in the recalls were the Burkholderia cepacia complex (34 occurrences), unspecified fungal contamination (19 occurrences), Bacillus cereus (9 occurrences), Pseudomonas aeruginosa (6 occurrences), Eli b thki i i ti (5 )Elizabethkingia meningoseptica (5 occurrences), Enterobacter gergovia (5 occurrences), Pseudomonas putida (3 occurrences) PseudomonasPseudomonas putida (3 occurrences), Pseudomonas spp. (2 occurrences) and Salmonella spp. (2 occurrences). )
August 4, 2014 IVT Microbiology Week 20
Burkholderia cepacia ComplexBurkholderia cepacia Complex
• The prominence of the Gram‐negative, oxidase‐The prominence of the Gram negative, oxidasepositive bacterium B. cepacia in non‐sterile product recalls is the result of it prevalence in water, metabolic versatility, and its resistance to many disinfectants and antimicrobial preservative
tsystems.• B. cepacia is a common opportunistic pathogen and infects cystic fibrosis sufferersinfects cystic fibrosis sufferers.
August 4, 2014 IVT Microbiology Week 21
Unidentified FungiUnidentified Fungi
• The second most prevalent recall category wasThe second most prevalent recall category was unidentified fungi. This reinforces that pharmaceutical microbiologists do a poor job identifying mold.
• For further information see Cundell, A. M. 2013 Mold Contamination in Pharmaceutical Drug products and Medical Devices European Pharmaceutical Review 18 (6): 67 75Pharmaceutical Review 18 (6): 67‐75
August 4, 2014 IVT Microbiology Week 22
Presentation OutlinePresentation Outline• The intention of the USP Microbiology Committee of Experts
• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non sterile drug• Extent of microbial contamination of non‐sterile drug products
• Content of the USP Chapter <1115>• Risk hierarchy by dosage form• Factors increasing microbial contamination risk• Drug substances• Drug substances• Pharmaceutical excipients• Role of Manufacturingg
August 4, 2014 IVT Microbiology Week 23
Contents of the USP Chapterp• Introduction• Risk Hierarchyy• USP <61>, <62> and <1111>• US Regulatory Guidance Documents• Microbial Control Consideration During Product Developmenti bi l C l C id i i• Microbial Control Consideration During
Manufacturing• Microbial Control of Drug Substance Manufacturing• Microbial Control of Drug Substance Manufacturing
– Equipment Design and use– Personnel
Th M f i E i– The Manufacturing Environment
August 4, 2014 IVT Microbiology Week 24
Content of the USP ChapterContent of the USP Chapter
• Microbial Assessment of Non‐sterile ProductMicrobial Assessment of Non sterile Product Manufacturing Environment– Microbial Sampling– Microbial Identification– Active Measures for Microbial Control
• Overall Management of a Microbiological Control• Overall Management of a Microbiological Control Program
• ReferencesReferences
August 4, 2014 IVT Microbiology Week 25
Presentation OutlinePresentation Outline• The intention of the USP Microbiology Committee of Experts
• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non sterile drug• Extent of microbial contamination of non‐sterile drug products
• Content of the USP Chapter <1115>• Risk hierarchy by non‐sterile dosage form• Factors increasing microbial contamination risk• Drug substances• Drug substances• Pharmaceutical excipients• Manufacturingg
August 4, 2014 IVT Microbiology Week 26
Risk HierarchyRisk HierarchyHierarchy of risk due to microbial contamination by route of administration (High to low):route of administration (High to low):
• Metered‐dose and dry powder inhalants• Nasal spraysp y• Otics• Vaginal suppositories• Topicals• Rectal suppositories• Oral liquids (aqueous)• Liquid‐filled capsules• Compressed tablets and powder filled capsule• Compressed tablets and powder‐filled capsule
August 4, 2014 IVT Microbiology Week 27
Presentation OutlinePresentation Outline• The intention of the USP Microbiology Committee of Experts
• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non sterile drug• Extent of microbial contamination of non‐sterile drug products
• Content of the USP Chapter <1115>• Risk hierarchy by dosage form• Other factors increasing microbial contamination risk• Drug substances• Drug substances• Pharmaceutical excipients• Manufacturingg
August 4, 2014 IVT Microbiology Week 28
Increased Microbial RiskIncreased Microbial Risk• The development of novel drug delivery systems e g dry powder inhalants nasal sprayse.g., dry powder inhalants, nasal sprays, transdermal patches, and drug‐coated transplanted medical devices that may increase
ti t i k t i bi l t i ti d tpatient risk to microbial contamination due to their invasiveness within the human body.
• The sourcing of drug substances fromThe sourcing of drug substances from manufacturing facilities in third‐ world countries with increased risk of potential product contamination due to poor GMPscontamination due to poor GMPs
• Globalization with drugs manufactured outside the US and transported around the world.the US and transported around the world.
August 4, 2014 IVT Microbiology Week 29
Increased Microbial RiskIncreased Microbial Risk
• The growth of off‐label dosage regimes andThe growth of off label dosage regimes and patient populations as physicians seek wider clinical applications and change administration pp gpractices.
• The increased aggressiveness and invasivenessThe increased aggressiveness and invasiveness of medical treatments.
• Increases in patients who due to their age orIncreases in patients who due to their age or medical condition are seriously immunologically compromised and are aggressively treated.p gg y
August 4, 2014 IVT Microbiology Week 30
Presentation OutlinePresentation Outline• The intention of the USP Microbiology Committee of Experts
• Expected impact of the new USP chapter <1115>• Extent of microbial contamination of non sterile drug• Extent of microbial contamination of non‐sterile drug products
• Content of the USP Chapter <1115>• Risk hierarchy by dosage form• Factors increasing microbial contamination risk• Drug substances• Drug substances• Pharmaceutical excipients• Manufacturingg
August 4, 2014 IVT Microbiology Week 31
Drug SubstancesDrug Substances
• The bioburden of DS manufactured by ychemical synthesis will largely depend on the final synthetic, isolation and purification steps the drying process micronization forsteps, the drying process, micronization for particle size reduction, and to a lesser extent the drug substance packaging. g p g g
• In general, the chemical transformations and isolation of intermediates typically involve
i i l dreactions using reagents, solvents, and elevated temperatures that are incompatible with the survival of microorganismswith the survival of microorganisms.
August 4, 2014 IVT Microbiology Week 32
Chemical SynthesisChemical Synthesis
August 4, 2014 IVT Microbiology Week 33
Drug SubstancesDrug Substances
• The bioburden of the starting materialsThe bioburden of the starting materials, reagents, and intermediates will have little or no impact on the bioburden of the drugno impact on the bioburden of the drug substances and may be discounted.
• The bioburden of a plant or animal derived• The bioburden of a plant‐ or animal‐derived drug substance will depend on the degree of processes of the materialprocesses of the material.
August 4, 2014 IVT Microbiology Week 34
Drug SubstancesDrug Substances
• The impact of the final purification and isolation e pact o t e a pu cat o a d so at osteps on the DS bioburden depends on the solvent used in the mother liquor, temperature f h l h l fof the isolation process, the inclusion of a
bioburden‐controlling filtration step, the material recovery method and drying processmaterial recovery method, and drying process.
• Typically 90% of the isolations employ organic solvent or a mixture of organic solvents andsolvent or a mixture of organic solvents and water and not water, which reduces the likelihood of microbial contamination.
August 4, 2014 IVT Microbiology Week 35
Drug SubstancesDrug Substances
• The most common organic solvents used in gindustrial organic syntheses include toluene, tetrahydrofuran, dichloromethane, ethyl acetate 2 propanol methanol denaturedacetate, 2‐propanol, methanol, denatured alcohol, acetic acid, n‐heptane, and acetronitrile. All are inimical to the survival of microorganisms
• If water is the primary solvent, purified i d f d i ilwater, USP is used for DS used in non‐sterile
drug products and low‐endotoxin purified water in sterile drug productswater in sterile drug products.
August 4, 2014 IVT Microbiology Week 36
Product DevelopmentPoints to be considered when assessing the potential microbial risk associated with non‐sterile d d tdrug products:
• Synthesis, isolation and final purification of the drug substance• Microbiological attributes of the drug substanceMicrobiological attributes of the drug substance• Formulation and physicochemical attributes of the drug product• Water activity of the drug product• Manufacturing process• Packaging and delivery system• Storage conditions of the drug substance and product• Storage conditions of the drug substance and product• Route of administration• Expected treatment procedure and dosage regimen• Age and health condition of the intended recipients of the drugAugust 4, 2014 IVT Microbiology Week 37
U.S. Regulatory DocumentsU.S. Regulatory Documents
• FDA Good Manufacturing Practices found in 21 CFRFDA Good Manufacturing Practices found in 21 CFR Part 211
• 211.42 Design and Construction• 211.46 Ventilation, Air Filtration. Air heating and Cooling• 211.56 Sanitation
• 211.113 Control of Microbiological Contamination
August 4, 2014 IVT Microbiology Week 38
Manufacturing Risk FactorsManufacturing Risk Factors
Microbial risk factors in descending order:Microbial risk factors in descending order:• Ingredient water• Pharmaceutical ingredientsg• Processing equipment• Manufacturing personnel• Manufacturing environment
August 4, 2014 IVT Microbiology Week 39
Pharmaceutical Water SystemsPharmaceutical Water Systems
August 4, 2014 IVT Microbiology Week 40
Classification of Pharmaceutical Excipients
• Binders • Caking agents• Disintegrants• Fillers (diluents)
Caking agents• Buffers• Preservatives
• Lubricants• Glidants (flow
• Preservatives• Suspending/dispersing agents
enhancers)• Compression aids
l
agents• Film formers/coatings• Flavors• Colors
• Sweeteners
• Flavors• Printing inks
August 4, 2014 IVT Microbiology Week 41
Common Excipients used in Solid Dosage Forms
Excipient Classification
Common ExcipientsClassificationDiluent or Filler Lactose, Sucrose, Kaolin, Dibasic Calcium Phosphate,
Calcium Sulfate, and Calcium CarbonateBinders Water Alcohol Starch Paste Gelatin SolutionsBinders Water, Alcohol, Starch Paste, Gelatin Solutions,
Tragacanth, Sodium Alginate, CarboxymethylCellulose, Polyethylene Glycol and Povidone
Lubricants Magnesium Stearate Calcium Stearate Talc StearicLubricants Magnesium Stearate, Calcium Stearate, Talc, Stearic Acid, Starch, Mineral Oil, Sodium Chloride, Sodium Benzoate, and Carbowax 4000 or 6000
Disintegrating Corn Starch Methylcellulose Sodium CarboxymethylDisintegrating Agents
Corn Starch, Methylcellulose, Sodium Carboxymethyl Cellulose, Alginic Acid, Microcrystalline Cellulose and Gums
Sweetening Mannitol, Lactose, Sorbitol, Fructose, Saccharine, and
August 4, 2014 IVT Microbiology Week 42
gAgents
, , , , ,Aspartame
Risk Analysis of Pharmaceutical ExcipientsExcipients
Classification Examples of Excipients Microbial RiskSynthetic Povidone (polyvinyl pyrrolidone) and Little or noneyMaterial
(p y y py )Crospovidone (A homopolymer of cross‐linked N‐vinyl‐2 pyrrolidone)
Semi‐synthetic Captisol (Chemically‐modified cylodextrin) Low to ymaterial
p ( y y )and Hydroxypropyl Methylcellulose moderate
Plant‐derived Material
Corn Starch, Microcrystalline Cellulose, and Sucrose
ModerateMaterial Sucrose
Animal‐derived Material
Lactose (Extractive), Magnesium Stearate (Processed chemically from tallow), and Gelatin (Purified from bone or hide)
Moderate to high
Material Gelatin (Purified from bone or hide)
Mineral‐derived Material
Talc (Extractive) and Dibasic Calcium Phosphate (Processed chemically from a mineral calcium carbonate and phosphoric
Low to moderate
August 4, 2014 IVT Microbiology Week 43
Material mineral calcium carbonate and phosphoric acid)
Talc MiningTalc Mining
August 4, 2014 IVT Microbiology Week 44
Lactose ProductionLactose Production
• Whey protein concentrates are powder made by drying y p p y y gthe retentate from the Ultra Filtration of whey. The concentration of whey proteins is primarily achieved by UF and DiafiltrationUF and Diafiltration.
• The permeate of UF membrane is high in lactose content, so that is used for manufacturing lactose
d d i dpowder. Permeate recovered is concentrated to minimum 62% TS level in an evaporator and then cooled under controlled conditions for Lactose crystallization. Crystals are washed, decanted and spray dried to produce pharma grade lactose.
August 4, 2014 IVT Microbiology Week 45
Lactose ManufacturingLactose Manufacturing
• Lactose spray dryerLactose spray dryer
August 4, 2014 IVT Microbiology Week 46
Risk AssessmentRisk Assessment
In Failure Mode and Effects Analysis (FMEA) terms y ( )risk was defined in terms of occurrence (O), severity (S) and detection (D). The risk is expressed as O x S X D Using this tool risk is minimized if occurrencesD. Using this tool, risk is minimized if occurrences decrease, severity of the effect of failure is decreased, and the efficiency of detection of a failure increases.
Note: The less readily that microbial contamination can be detected the higher the value of D and the overall riskoverall risk.
For a discussion of risk analysis see ICH Q9 Quality Risk Management
August 4, 2014 IVT Microbiology Week 47
Simple Risk AnalysisSimple Risk AnalysisAn approach is to assign a score from 1 to 3 to pp gthe following:
• Severity (S) as a consequence of failure• Occurrence (O) as the likelihood of failure occurring based on past experience
• Detection (D) as the likelihood that failure detection will take place with the proposed monitoring system
• The risk is determined by the product of S x O D
August 4, 2014 IVT Microbiology Week 48
x D
Risk Analysis – Occurrences (O), b l ( ) d b l ( )Susceptibility (S) and Detectability (D)
Excipient O S D O x S x DpManufacturing ProcessSynthetic Material 1 2 1 2
Semi-synthetic material
1 2 2 4
Plant-derived Material
2 3 2 12
Animal derived 3 3 2 18Animal-derived Material
3 3 2 18
Mineral-derived Material
2 2 2 8
August 4, 2014 IVT Microbiology Week 49
Material
ICH Q6AICH Q6A
• For drug product release testing, ICH Q6A Test g p g, QProcedures and Acceptance Criteria for New Drug Substances and Drug Products provides decision trees that guide manufacturers on necessary testtrees that guide manufacturers on necessary test strategies based on the nature of the product.
• The establishment of microbiological attributes areThe establishment of microbiological attributes are described in Decision Tree 6 (Drug Substances) and Decision Tree 8 (Drug Products).
• Low water activity is a highlighted attribute for reduced testing strategies.
August 4, 2014 IVT Microbiology Week 50
Manufacturing EnvironmentCommon design elements to control microbial contamination:
• Non‐porous walls, ceilings and floors that are readily cleanable• Floor drains that can be closed during processing or fitted with
a air break if opened during area and equipment cleaning• Access should be limited to essential personnel
M t i l i t d l fl h ld id• Material, equipment and personnel flows should avoid contamination
• Ventilation and air filtration should be adequate to maintain qthe specified cleanliness, space pressurization, temperature and humidity
August 4, 2014 IVT Microbiology Week 51
Manufacturing EquipmentManufacturing Equipment
For bioburden control equipment should have theFor bioburden control equipment should have the following attributes:
• Sanitary designy g• Readily cleaned preferably using a CIP system• Self‐draining to eliminate stagnate waterSelf draining to eliminate stagnate water• Preventative maintenance program to periodically replace valves, seals, filters and hosingp , , g
• Inclusion of microbial monitoring in cleaning validation protocolsp
August 4, 2014 IVT Microbiology Week 52
Dosage FormsDosage Forms Over 80% of the current drug products by the number of prescription are marketed as oral solidnumber of prescription are marketed as oral solid dosage forms, i.e. powder‐ and liquid‐ filled capsules and compressed tablets, which have a very low risk of microbial contamination because of their manufacturing processes, low water activity and route of administrationroute of administration.
Many other non‐sterile drug products, e.g., oral liquids, topicals, nasal sprays, etc, may be q , p , p y , , ysusceptible to microbial growth and have more critical routes of administration than an oral solid.
August 4, 2014 IVT Microbiology Week 53
Risk AssessmentRisk Assessment
What other tools are available for this risk assessment? In the 1960's, the Pillsbury Company, the U.S. Army, and National Aeronautics and Space Administration (NASA) i t d d t f i th(NASA) introduced a system for assuring pathogen‐free foods for the space program.
This system, called Hazard Analysis and Critical This system, called Hazard Analysis and Critical Control Points (HACCP), is a focus on critical food safety areas as part of total quality programs and may be a tool applicable to the pharmaceutical industrybe a tool applicable to the pharmaceutical industry.
August 4, 2014 IVT Microbiology Week 54
HACCPHACCP
• HACCP involves a critical examination of theHACCP involves a critical examination of the entire food manufacturing process to determine every step where there is adetermine every step where there is a possibility of physical, chemical, or microbiological contamination of the foodmicrobiological contamination of the food, which would render it unsafe or unacceptable for human consumption. Theseunacceptable for human consumption. These identified points are the critical control points (CCP).points (CCP).
August 4, 2014 IVT Microbiology Week 55
HACCPHACCP
There are seven principles to HACCP:There are seven principles to HACCP:1. Analyze hazards, 2 determine CCPs2. determine CCPs, 3. establish critical limits, 4 establish monitoring procedures4. establish monitoring procedures,5. establish deviation procedures, 6 establish verification procedures and6. establish verification procedures, and 7. establish record keeping procedures
August 4, 2014 IVT Microbiology Week 56
Tablet ManufacturingTablet Manufacturing
In general, the most critical processing steps with g , p g prespect to potential microbial contamination are the procurement of pharmaceutical ingredients, wet granulation and milling and tablet coatingwet granulation and milling and tablet coating (Bolded red in list of manufacturing steps). For example, the holding time of aqueous film coating p g q gsolutions may be a critical control point.
In contrast, fluid bed drying and compression are t ti ll bi b d d ti t (B ld dpotentially bioburden‐reduction steps (Bolded
green)
August 4, 2014 IVT Microbiology Week 57
Tablet ManufacturingTablet ManufacturingFor example, the processing steps for the manufacture of a film‐coated compressed tablet are:of a film coated compressed tablet are:
Procurement of pharmaceutical ingredients Warehousing pharmaceutical ingredients Batching of the pharmaceutical ingredients Blending
l i d illi Wet granulation and milling Drying Tablet compression Tablet compression Tablet coating Packagingg g DistributionAugust 4, 2014 IVT Microbiology Week 58
Tablet ManufacturingTablet Manufacturing
• Unit processes involved in making tablets includeUnit processes involved in making tablets include particle size reduction and sizing (milling), blending, granulation, drying, compaction (compression), (frequently) coating and packaging.
August 4, 2014 IVT Microbiology Week 59
Tablet ManufacturingTablet Manufacturing
August 4, 2014 IVT Microbiology Week 60
Risk Analysis for Tablet ManufacturingRisk Analysis for Tablet Manufacturing
Manufacturing Step
Contamination Potential
Preventative Measures/Critical Control Points
Remarks
Wet granulationand milling
Moderate Equipment design. Cleaning validation.
Emphasis on water system validation and equipment cleaning to
Monitor purified water used in granulation solutions for
prevent microbial contamination. Water activity measurement may be used to evaluate
microbial counts (CCP). Holding Time (CCP).
the ability of the granulation to support microbial growth
August 4, 2014 IVT Microbiology Week 61
Risk Analysis for Tablet ManufacturingRisk Analysis for Tablet ManufacturingManufacturing Step
Contamination Potential
Preventative Measures/Critical
Remarks
Control Points
Tablet Coating Moderate to Equipment Water-based High cleaning and
solution holding time (CCP)Incoming
coating solution will support microbial growth.
microbial testing of ingredients (CCP)Monitor purified
Holding times need to be justified.
Monitor purified water used in coating solutions for microbial counts (CCP)
August 4, 2014 IVT Microbiology Week 62
counts (CCP)
Risk AnalysisRisk Analysis
• After Anastasia Lois, 2013After Anastasia Lois, 2013
August 4, 2014 IVT Microbiology Week 63
ConclusionsConclusions
The management of a successful microbiological g gcontrol program includes the following:
• Identification of suitable suppliers of h l d d h hpharmaceutical ingredients and excipients that have
good microbiological quality• Conducting a microbial risk assessment of the drug• Conducting a microbial risk assessment of the drug formulation, manufacturing process and packaging system and mitigating those risks
• The establishment of an appropriate monitoring and control system.
August 4, 2014 IVT Microbiology Week 64
Contact InformationContact Information
• Tony Cundell, Consulting MicrobiologistTony Cundell, Consulting Microbiologist• Email address: tonycundell@gmail.com• Phone number: 01 914 725‐3947Phone number: 01 914 725 3947
August 4, 2014 IVT Microbiology Week 65
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