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Aqueous Cleaning - Benefits
Aqueous Cleaning - Benefits
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Applications in
Pharmaceutical Manufacturing
About Aqueous
Cleaners 1
The Benefits of Aqueous Critical Cleaning
The Aqueous Critical
Cleaning Process
The use of aqueous cleaning in pharmaceutical manufacturing can provide numerous
Selecting the Proper
Aqueous Cleaner benefits in terms of effectiveness, minimal surface residue, and easier cleaning
Removing Surface validation. Virtually any pharmaceutical manufacturing equipment — from tablet
Pyrogens and
Endotoxins 2 presses to a stainless steel mixing tanks — can be cleaned to stringent critically
The Role of pH and clean criteria by aqueous cleaning.
Residue 3
The Role of pH and
Substrates
Removing Stearic About Aqueous Cleaners available in low toxicity formulations that make
Acid from Stainless Aqueous cleaners are typically formulated to achieving acceptable residue levels easy during
Steel 4
ensure maximal cleaning performance by using cleaning validations. Even multi-product facilities
Choosing the Right
Method key ingredients such as surface active agents can often find a single aqueous cleaner that cleans
Automated (surfactants) — excellent wetting agents that allow all residues on all surfaces. This lowers costs for the
Clean-in-Place (CIP) 5
the cleaning solution to penetrate into crevices while manufacturer because only one cleaner has to be
Spray CIP
Immersion CIP getting under soils to allow for removal. Often very validated.
Manual Cleaning dilute solutions of aqueous cleaner will effectively Aqueous cleaners are suitable for all variety
Machine Washers 6 remove even worst-case substances from a variety of cleaning methods commonly used in pharmaceutical
Cleaning Validation
Method Guidelines 7 hard surfaces, including stainless steel, glass, plastic, manufacturing:
Case Study or porcelain. • Manual
An Aqueous Cleaner The proper use of aqueous cleaning helps • Soak
for Every Application 8
manufacturers minimize surface residue and makes • Machine
Get Validation
Support 10 cleaning validation easier. Aqueous cleaners are • Automated clean-in-place (CIP)
positive-positive repulsion may be achieved. At the cleaning are achieved when the automated CIP
very least, by lowering the pH, a neutral residue and system is integrated into the original design of the
a positive surface are created, with no attraction manufacturing equipment; however, existing tanks are
between them that would make cleaning difficult (see often retrofitted with automated CIP systems.
Table 3). There are often monitoring systems, also known
as process-control instrumentation, to ensure all
Choosing the Right Method of Aqueous parts of the system are functioning correctly and the
Cleaning in Pharmaceutical Manufacturing process is being done according to the program.
According to FDA According to FDA rationale, cleaning equipment is The automated equipment has sensors and data
rationale, cleaning meant to be designed to “prevent contamination recorders to document the cleaning and can create
or adulteration of drug products.” Typically reports that will become part of the batch log to
equipment
pharmaceutical operations require transition from document that the cleaning was done correctly for
is meant to bench-scale R&D to pilot studies to full-scale regulatory compliance.
be designed manufacturing. Cleaning at each stage requires Automated CIP systems typically comprise the
to “prevent careful consideration of the size and configuration following components and subsystems:
contamination or of the processing equipment and suitable cleaning • Primary water source — Used to make
adulteration of techniques. In general, the equipment increases in up the cleaning solutions and as rinse water
drug products.” size at each subsequent stage. Consequently, manual before and after the cleaning cycles. Can be
cleaning and soak cleaning tend to be adequate for heated, if necessary.
bench-scale equipment, whereas pilot and large- • External tank — Can be used for mixing and
scale manufacturing process equipment usually storing the cleaning solutions. Sometimes the
requires clean-in-place (CIP) cleaning by automated manufacturing tank is used for this purpose.
spray or immersion systems and/or by manual • Separate external tank — Holds rinse
cleaning. water. A second source of water can also be
All stages of development and production may employed if the final rinse requires purified
use manual cleaning or machine washers to clean water such as WFI or deionized (DI) water.
various parts of equipment or utensils. If feasible, it is • Pumps and piping — Connects external CIP
preferable to clean the pharmaceutical equipment in tanks to the manufacturing equipment to be
place, without disassembling or moving it, in order to cleaned. A water conservation system can be
rapidly get the equipment back into service. installed that pumps the final rinse water into
the cleaning solution dilution tank for use in the
Automated Clean-in-Place (CIP) first cleaning cycle of the next automated CIP
Automated clean-in-place systems for pharmaceutical run.
manufacturing equipment typically use either spray • Automated controllers — Run the pumps
or immersion cleaning. Automated CIP systems and control the dosing of cleaning agent
can be permanently integrated into a set of and water. Either fully automated, or semi-
manufacturing tanks, or they can be on mobile skids automated programs that require operator
that are moved from tank system to tank system, as intervention at key steps in the process.
needed. Typically, the best results with automated