Containers aseptic manufacturing

Because of these product sensitivities, most ophthalmic pharmaceutical products are aseptically manufactured and filled into previously sterilized containers in aseptic environments using aseptic filling-and-capping techniques. This is the case for ophthalmic solutions, suspensions, and ointments, and specialized technology is involved in their manufacture. 

Laminar flow sterilization tunnels are widely used in high-speed aseptic manufacturing. Typically, laminar flow tunnels contain three sections (1) preheating, (2) heating, and (3) cooling. 

Broth fills should be carried out under conditions that are representative of those during normal operation. If there is to be a deviation from routine processes, it should only be in the direction of presenting a greater, rather than a lesser, challenge to the process. Due to the level of automation of BFS technology, it is extremely difficult to take extra care in order to reduce the chance of container contamination during a broth fill therefore, results are not as operator-dependent as other less automated aseptic manufacturing processes. 

Blow/fill/seal units are purpose-built pieces of equipment, which carry out these three steps in a continuous process within a controlled environment. Containers, which are formed from thermoplastic granules, are blown to form the correct shape, filled and heat-sealed. These units are fitted with a grade A air shower and operated in a grade C environment for aseptic manufacture and a grade D background for products which are to be terminally sterilized. 

In the case of injectables and ophthalmic preparations which are manufactured aseptically but do not receive a sterilization treatment in their final container the packaging has to be sterilized. Dry heat at 170°C is often used for vials and ampoules. Containers and closures may also be sterilized by moist heat, chemicals and irradiation, but consideration for the destruction or removal of bacterial pyrogens may be necessary. 

When an ophthalmic ointment is manufactured, all raw material components must be rendered sterile before compounding unless the ointment contains an aqueous fraction that can be sterilized by heat, filtration, or ionizing radiation. The ointment base is sterilized by heat and appropriately filtered while molten to remove extraneous foreign particulate matter. It is then placed into a sterile steam-jacketed kettle to maintain the ointment in a molten state under aseptic conditions, and the previously sterilized active ingredients) and excipients are added aseptically. While still molten, the entire ointment may be passed through a previously sterilized colloid mill for adequate dispersion of the insoluble components. 

A suitable holding tank is sterilized in place by steam. The following sterilized parts are aseptically connected to the tank a blender valve, a safety relief valve, and a vent filter assembly containing a 0.2 im filter. Prepare the media according to manufacturer instruction. Adjust pH. 

This document contains information related to the liquid aseptic fill operation used in the manufacture of (product name), USP, at ABC Pharmaceutical Industries located at (provide postal address). Additional information to support the liquid aseptic filling validation includes but is not limited to environmental monitoring and controls, as well as product-specific testing such as bioburden and sterility testing. The main subsections are ... 

The sterile milk concentrate is aseptically placed in suitable containers, probably metal cans or modem laminated, foil-lined, plastic containers. Modern aseptic packaging equipment used for manufacturing UHT sterile milk should be satisfactory for packaging the sterile milk concentrate. 

Sterile radiopharmaceuticals may be divided into those which are manufactured aseptically and those which are terminally sterilized. In general, it is advisable to use a terminal sterilization whenever this is possible. Terminal sterilization is defined as a process that subjects the combined product/container/closure system to a sterilization process that results in a specified assurance of sterility [7], Since sterilization of solutions normally means autoclaving (steam sterilization), one must assure that the radiopharmaceutical product does not decompose when it is heated to temperatures above 120°C. Many radiolabeled compounds are susceptible to decomposition at higher temperatures. Proteins, such as albumin, are good examples of this. Others, such as 18F-fluodeoxyglucose (FDG), can be autoclaved in some formulation but not in others. 

Some sterile powder formulations (these are predominantly, but not exclusively, antibiotics) may require sampling, mixing, milling, and subdivision activities similar to those found in oral powder manufacturing. The facilities and equipment utilized for these products is substantially different from that used for liquids, and the production area bears little resemblance to that utilized for liquids. These materials are received sterile and must be processed through sterilized equipment specifically intended for powder handling in a fully aseptic environment with ISO 5 protection over all open container activities. 

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