Professional Documents
Culture Documents
GMP Pharmaceutical Facility Design Slide
GMP Pharmaceutical Facility Design Slide
Pharmaceutical Facilities
Process design
Layouts and Flow Diagrams
OSD Facilities
Biopharma and Aseptic facilities
Speaker - Leonid Shnayder, Ph.D, P.E.
2
Speaker - Leonid Shnayder, Ph.D, P.E.
Courses taught:
Intro to Pharma Manufacturing
Validation in Pharma Manufacturing
GMP in Pharma Facilities Design
Manufacturing of Biopharmaceutical Products
Manufacturing and Packaging of Oral Solid Dosage Products
Statistical Methods in Pharma Manufacturing
Leonid.Shnayder@stevens.edu
3
PME Program at Stevens Institute of
Technology
Master of Science in Pharma Manufacturing degree
10 courses (5 foundation plus 5 elective courses)
All PME courses are offered in both on-campus and online
delivery modes. It is possible to earn the degree entirely online
Applicants must have Bachelors degree in science, pharmacy
or engineering
Graduate Certificates
Pharmaceutical Manufacturing
Validation, Compliance and Quality
4 courses each
4
Current Good Manufacturing Practices
(cGMP)
cGMP is a set of regulations published by the US Food
and Drug Administration (FDA)
Most national and international agencies regulating
pharma industry have similar regulations or guidelines
cGMP regulations cover many aspects: organization
and personnel, building and facilities, equipment,
control of components, production controls,
packaging and labeling controls, laboratory controls
etc.)
Well discuss aspects related to building and facilities
and equipment
5
GMP Requirements Highlights
6
Process design considerations
7
Process Design Tools
Process description
Block Flow Diagrams (BFD)
Process Flow Diagrams (PFDs)
Piping and Instrumentation Diagrams (P&IDs)
Material and energy balances
Process and utility equipment list
Utility requirements table
Instrument list
Equipment specifications and/or Data Sheets
Piping specs
8
Block Flow Diagram Tablet
Manufacturing
Active Ingredient 1 6 Raw Material
Excipient 4 9 Lubricant
1 2 3 4 5 6 7 8 9 10
Raw Material 5 10 Raw Material
2 3 4
Dry
5 6 7 8 9 10
Mill
Blend
Blend
11 Purified Water/Solvent
Compress
9
Block Flow Diagram and its Uses
10
Process Flow Diagrams (PFDs)
11
Process Flow Diagram
12
Process Flow Diagrams
13
Personnel Flow & Gowning Diagram
14
Material Flow Diagram
15
Portable Equipment Flow Diagram
16
Process and Facility Design - Summary
17
Building Materials
Clean Room Features
19
Clean Room Features (contd)
20
Examples of Modular Clean Rooms
21
Building Materials and Finishes -
Summary
Materials and Finishes are selected for suitability within
every select environment in the facility.
A very informed basis of understanding is required to
properly select materials and finishes. Knowledge of
the manufacturing process(s), SOPs, staff activities and
maintenance needs for all areas within the facility are
vital to a successful solution.
22
Manufacturing of Solid Dosage
Products
24
Guiding Principles for Regulatory
Compliance
Environmental
Provide suitable conditions of temperature, humidity, and
particulate control
Prevent cross contamination
Prevent microbial growth or infestation
Facilities and Equipment
Surfaces that will not contaminate
Provide ease of cleaning and maintenance
25
Contamination and Level of Protection
Criteria
Potential Contamination Sources
HVAC Systems
Process equipment cleanliness
Room construction issues
Containerization and transport of materials
Personnel
Infiltration from other areas
26
Unit Operations in Solid
Dosage Manufacturing
Unit Operations and Equipment
Applications
28
Dispensing
29
Technical Considerations for API
Dispensing Systems
Split
Butterfly
APIs typically handled in small amounts Valve
Occupational Exposure Limits
Handled in a Controlled or Contained
Environment:
Dust collection systems for benign materials
Down flow booths for low toxicity materials
Closed systems with split valve technology for
high toxicity materials
Glove Box Isolators for the most toxic
materials
Personal Protection Equipment
Isolator
30
Other Design Considerations
31
Sifting and Classifying
Purpose:
De-lumping of powders
Improve particle size
distribution - removal of
oversized and undersized
particles
Equipment:
Vibratory screen sifters
Manual sieves
32
Milling
Used for:
Particle size reduction
Change particle shape
De-lumping
33
Wet Granulation
High Shear
Granulation
High dispersion
Improved
homogeneity
Good for small
quantities of
actives
34
Wet Granulation contd
35
Drying
36
Blending
37
Tablet Compression
38
Encapsulation
Capsules
Hard gelatin capsules filled with
solids
Final blend must be uniform
Better for products with high API
content
Filling done by volume, so
constant bulk density is important
39
Coating
40
Coating
41
Facility Layout
42
Layout of Mixing and Granulating
Areas
Easy movement of materials
into separate processing
rooms
Minimize cross-
contamination potential
Air pressure in the corridor is
higher than in the process
rooms for product
containment
43
Design Considerations for OSD -
Summary
HVAC
Air Filtration
Negative room pressurization
Dealing with dust generation:
Dust collection
Closed processing
Cleaning
Containers must be moved to wash area for cleaning
Risk of spreading contaminants through the facility
May provide wash or vacuum cleaning capability inside process
room
44
BioPharmaceutical
Manufacturing Facilities
46
Process Block Flow Diagram
47
Building Design Considerations
Operational Efficiency
Operational Safety
Protection of Product from contamination
Protection of Personnel
Protection of Facility
Maintainability
48
Program Design Considerations
Equipment Arrangements
Material Flow
Personnel Flow
Product Flow
Waste Flow
Adjacencies
Segregation
Flexibility
Expandability
49
Single Product Facility with Minimal
Segregation
50
Single Product Facility with Moderate
Segregation
51
Multi-Product Facility with Moderate
Segregation
52
Layout Considerations - Summary
53
Classification of Clean Rooms
54
HVAC Techniques
55
Air Filtration
56
Air Filtration
57
Air Pressurization
58
Air Pressurization
59
Air Pressurization
60
Air Pressurization Diagram
61
Air Locks Types
Sink
3 '-0 "
3 '- 0 "
MAL
Cascade
62
Personnel Air Lock
63
Material Air Lock
64
Air Flow Diagram
65
Air Quality Monitoring
Source - www.metone.com
66
HVAC - Summary
67
Single- and Multi-product Plants
68
Equipment and Piping Design
Concepts
Most large plants have fixed stainless steel equipment
and fixed process piping
Flexibility can be achieved by using flexible piping
(hoses) in addition to the fixed piping
Many smaller plants use disposable equipment
storage bags, fermentation bags, , filters etc.
69
Plant Design Concepts - Summary
70
Aseptic Processing Facilities
Introduction
72
Containers for Aseptic Products
Examples:
Vial (sealed using a rubber stopper and aluminum
seal)
Ampoule (a glass container sealed using heat
directly after filling)
Syringe (sealed with a rubber stopper and a needle
cover)
Plastic bottle (sealed with a plastic cap)
Blow-Fill-Sealed Bottles (a plastic bottle that is made
filled and sealed in one step)
73
Sterile Dosage Forms
Bottles
Blow-fill-
seal vials
74
1. Prep Bulk 6. Wash Vials 2. Prep & 3. Wash & 4. Prep
Product Sterilize Change Sterilize Overseals
Parts Stoppers
2. Filter 7. 5. Assemble
Sterilize Bulk Depyrogenate Change Parts
Product Vials
8. Fill Vials
8. Check
Weigh Vials
8. Stopper
Vials
9. Overseal
Vials
10. Inspect
Vials
12. The Background Environment
11. Package
Vials
ISO 5
ISO 8
75
The Vial Filling Process
76
Vial Filling and Stoppering
Orienting stoppers
Vial Filling
77
Inspect Vials
78
The Vial Filling Process
79
The Vial Filling Process
80
The Vial Filling Process
81
Clean Room
82
The Vial Filling Process
Isolators:
box around the process
access the process via
gloves
must be
decontaminated using
automated technology
(VHP or H2O2) because
the clean zone is very
small
83
The Vial Filling Process
Advantages of isolators:
The operator is removed from the process, so less product
risk
Can be located in an ISO8 environment
Reduced ISO5 area
Reduced requirements for the sterile garb
Fewer airlocks and material sanitization steps
Material and people movement in the facility is simplified
Cleaning and cleaning validation reduced
Lower long term operation cost than traditional clean
room facility
84
The Vial Filling Process: Isolators or
RABS?
RABS
Concept - to combine the
advantages of an isolator
with the flexibility of a clean
room
In reality RABS has not solved
any of the perceived
disadvantages of an isolator.
85
Factors affecting Aseptic Filling -
Summary
86
References
1. cGMP Regulations:
https://www.accessdata.fda.gov/scripts/cdrh/cfd
ocs/cfCFR/CFRSearch.cfm?CFRPart=211
2. ISPE Biopharmaceutical Manufacturing Facilities
Baseline Guide www.ispe.org
3. International Standard ISO14644-1Cleanrooms
and associated controlled environments Part
1: Classification of air cleanliness. 2015.
87
Questions?
88
Regulatory requirement for
Pharmaceutical facilities
.
16 2560
GMP ..2559
GMP ..2559
()
() 4
Food and Drug Administration3
A
C
D
A
C
D
The Inspectorate
Food and Drug Administration3
/ /
Air Lock
Air Lock
IPC ///
IPC
//
/
Air Lock
/
Air
Lock
Food and Drug Administration
Penicillin non-sterile critical area
18+10%RH
A/L -1
+1 -1
Sub - Corridor
0
A/L 18+10%RH
+1
6.00
-1 -1
18+10%RH
A/L
0
-1 -1 -1
-1
18+10%RH 18+10%RH -1
0
0 Corridor
Corridor
6.00
Dry
Corridor
A/S -1
-1 +1
-2 -1 / IPC syrup
-1
-1
-1
Corridor
+1
0 A/L 10+10%RH +1
10+10%RH
A/L +1
Alu Alu
Bench
+1 Alu PVC -1 /
-1 (Strip pack) -1
(Blister pack)
LIFT
6.00
A/L A/L
0 Corridor -1
+1 0 -1
MOB
Albert Einstein
WORLD CLASS PHARMA FACILITY
PRESENT SCENARIO :
The Globalization & Open Market Policy has proved to be a boon for the
industries, but has generated need for a globally acceptable
manufacturing facility.
There are many flourishing manufacturing facilities, but not all are in
compliance with the various regulatory standards.
Technology
Execution
Building services Approvals (non-pharmaceutical)
Building technology
Pharmaceutical regulations,
EU, FDA, PIC/S, WHO, requirements of
pharmacy inspectors, product registration ...
Norms
ISO, ATEX, etc...
Process / Equipment
GMP and Hygiene Zoning
Quantitative data
Layout
CONVENTIONAL MODEL
IMPROVED MODEL
Not to scale
FEASIBILITY VERSUS CONCEPTUAL STUDY
Task Definition
Targets Requirements
easy
Analysis
Conceptual Design
with Alternatives
difficult
Basic Design
Detail Design
Execution
RELATIVE COSTS OF THE DIFFERENT PHASES
Factory size
100%
Factory organisation
Technology
90% GMP concept
80%
Conceptual Design
70% Basic Design
60%
Detail Engineering Execution
50%
40%
30%
20%
10%
Costs
saving potential Small teams
Brainstorming
100% Alternatives
Factory size
New ideas
90% Factory organization
Technology
80% GMP
70% Conceptual Design
60%
10%
Tender documents
Detail design
Offers
Execution
Supervision Final quotations
Documentation
PRICE PAID
PRECISION OF COSTS
in relation to the planning stage stage
Execution
Final Quotations
Supervision
5%
Documentation
DETERMINATION OF COSTS
in relation to the planning system
- +
Feasibility
Conceptual design
Turnkey price:
Basic design poor control
General planner:
Detail design good control
Execution
Supervision
Documentation
TARGETS OF PHARMACEUTICAL FACTORY
PLANNING
Layout
General Factory Organisation Procedures
Hygiene Concept
Technology Concept
Air Handling and Utilities Concepts
US FDA / Europe
It is not an establishment inspection report
There are no Inspectional Observations
It is a candid dialogue regarding potential issues (Red Flags)
The outcome represents the opinion of an inspector, not necessarily
that of the FDA
Agencies act as consultants, not as police
ASIA
No dialogue
Inspector can block further work, by imposing his point of view
No appeal possibility in the practice (respect of authority, fear of later
potential problems)
EXAMPLES OF STATEMENTS BY INSPECTORS
Right team
Some fantasy
PEOPLE AND PLANNING
A Quote:
Albert Einstein
CORE TEAM
Quality Assurance
Production Manager
Integrated Factory
Planning Experts
AD HOC MEMBERS
Utilities Specialist
Controller
Other Specialists
Logistics
Engineering
PEOPLE AND PLANNING
Generalists Specialists
Number of people
PLANNING
Number of people
Generalists Specialists
VALIDATION
JUDGEMENT ERRORS
100%
90%
80%
Judgement Errors
70%
60%
Large
50%
Organisations
40%
30%
Individuals
20%
Concept
10%
Team
Number of Participants
Role of Participants :
To plan AND to decide
PLANNING METHODS
By Systematic Planning
By Turnkey Contracting
OPTIMAL PLANNING METHOD
Masterplan
Departments
Functional groups
Economy of scale
Efficiency / Best practice
Flexibility
Performance
Organisation
Analysis of
Product range
Process Conceptional design
Technologies Make or buy
Organisation Specialisation
Capacity increase
Technology
Requirements Standardisation
Vision Regulatory aspects
Results versus costs
of client
PLANNING METHOD
DEVELOPMENT OF IDEAL ORGANISATION
Information Strategy Resulting Organisation
Verification
Analysis Identification process flow, Combination
process key problems material flow material flows
functional
Analysis Other inter-
Material / requirements, dependencies
Information constraints,
flow etc.
Plant Definition
Idenfication
strategy Modules
necessary Verification B/W-
Functional
infrastructure GMP Orientation
+ units
concept of factory
Vertical
Process Horizontal
Analysis of architecture
products Calculation Rough
Analysis space necessary layout
and
situation space development
production
volumes
Definition of
Analysis Layout
constraints,
machinery / alternatives
etc.
equipment
Adaptation
Analysis Evaluation
Process,
organisation +
machinery +
Selection
equipment
START END
PLANNING METHOD
RATIONALISATION, INNOVATION AND OPTIMISATION
Forecasts, Product
Quantities, Seasonality
Plant Product Mix
strategy Campaign Sizes
Batch Sizes
+ Cleaning +
Galenical Change-over
Process Properties Times
architecture
PLANNING PROCEDURE: CONCEPTUAL DESIGN
Production forecasts / next 6-10 years
Definition of
- Process technology
- Machinery + equipment Definition of personnel,
- Transport systems + containers shifts, etc.
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client:
size, degree of sophistication, automated guided vehicles,
architecture, budget, future-oriented or not
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Safety of operator
Vision of client
Properties of products to be processed:
eg granulation properties: is a direct compression possible or a
dry granulation ?
Aseptic processing or terminal sterilization, ampoules or
syringes
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
High capacity / one shift, low capacity / 2 or 3 shifts
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
fully automated preparation of solutions, with CIP/SIP,
equipment for solids with CIP capability, cartoning,
palettisation, etc.
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues Q
U
Safety of operator A
N AUTOMATION
T POSSIBILITIES
T
I
T
E
S NUMBER OF
PRODUCTS
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Can influence the type or the supplier: eg difference in size
between FBG and one-pot system
Previous experience, available equipment (standardization)
GMP issues
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Aseptic processing problems: automated loading of freeze-
dryer, increased automation, increased sterility assurance level
Safety of operator
SELECTION OF TECHNOLOGY AND EQUIPMENT
Vision of client
Properties of products to be processed
Output requirements
Degree of automation, sophistication
Supplier: price, service and serviceability
Cleanability and maintenance needs
Space constraints
Previous experience, available equipment (standardization)
GMP issues
Safety of operator: containment or PPE ?
A B
WSG
WSG
MC
MC MC
MC
MC
MC
MC
MC MC MC MC
MC
vibrati on sieve
MC MC
MC MC
A: B:
Feed ing l evel
granules + l ubri cants
Personnel+ t rade powders
P
( + formulat ions for direct
T ransp o rt
MC compresi on)
T echnical Ar ea
( + formulat ions for direct compresi on)
T echnical ar ea
C or rid o r o r Visi to rs
TP
T ech.
C or rid o r
Personnel
Personnel+
P T ransp o rt
C or rid o r
P
T echnical ar ea
T ech.
MC
TP
C or rid o r
Personnel
PLANNING METHOD
PROCESS AND ORGANIZATION FLOW CHARTS
Drying
Sieving
Addition
lubricants
Blending
Compression
PLANNING METHOD
ORGANIZATION FLOWCHART (EXAMPLE: SOLIDS)
Granulation
Binder
preparation
Drying
Staging
m2 ? Sieving
Addition
Weighing lubricants
Staging
Blending m2 ?
Staging
m2 ? Staging
Compression m2 ?
Container
washing
PLANNING METHOD
FLOWS PERSONNEL AND MATERIALS
Exterior Exterior
Lockers G
Lockers G Lockers D
Lockers D
G D
G D
Lockers C
Lockers A/B
Lockers C
Lockers A/B C
C A/B
A/B
BULK
QA
QC
CLEAN BULK CENTRAL
UTILITIES WH WH LOCKERS
FORM
FILL
W QUA
S R
UTIL
PACKAGING
BLACK
STRONG RELATION
WEAK RELATION
NO RELEVANCE
PERSONNEL LOCKERS
EXAMPLE LAYOUT
Depend on
Hygiene zone
Local regulations
Company / cultural habits to be considered
IDEAL LAYOUT MATERIAL / PERSONNEL FLOW PLANNING
FACTORY ORGANISATION
MATERIAL SUPPLY ROUTES
LF
PRIMRVERPACKUNG SEKUNDRVERPACKUNG
PRIMRVERPACKUNG SEKUNDRVERPACKUNG
LF
PRIMR
EXAMPLE SUPPLY ROUTES MATERIALS
Basement
Black Area Locker
Results
WB
Pumpe
IPC
Ansatz
Alu
Technik
Hebeeinrichtung
Plattform
Paletten-Umwandlung
Ent nahme Ent nahme
Kilian TX
Handlager fr Komm iss. Fe rt igpackg. (verschlie ba r)
Pac kti sc he
Kommi ss. Pakete
Pac kti sc h
Plattform
Rol lenbahn
Lackieren Pult
Hebeeinrichtung
Gabelstapler
Kilian T300
Pa lettier er
P ERS.
Schleuse
P roben
LF
Bnd elp ac k er
Granulation
Wa age
F alts c hac ht el
K ar tonier er
Prozesstechnik
Plattform
Prozesstechnik
FROM IDEAL MODULE TO FACTORY LAYOUT
From
process to
space organisation
Step 1
From
process to
space organisation
Step 3
EXAMPLE OF CONCEPT FOR SOLIDS PRODUCTION
EXAMPLE OF CONCEPT FOR SOLIDS PRODUCTION
SITE LAYOUT
LOGISTICS
Production
Storage activities
Main storage
Special storages Exterior
Clients
Logistic centre
LOGISTICS
Raw material
Primary packaging material
Secundary packaging material
Finished products
pal / h
Receiving pal / h pal / h Production
pal / h
weighing
for raw - and primary
Warehouse
packaging material
area pal / h area
Preparation area
Sampling Pharma
Booth
pal / h
pal / h
pal / h
pal / h
Shipping Storage
capacity:
pal / h pal / h
pal / h
pallet
places
Bulk store
pal / h pal / h Packaging
Marshalling pal / h
lines
Overkill
Cost issues
Nice to have
GMP is not an attribute, no black and white attitudes
SUMMARY