【正文】 rated from the surrounding room environment by a sterilizing grade vent filters. Leak testing must occur pre and post use to demonstrate the system integrity. EQUIPMENT AND PROCESS SYSTEM IMPACT ON FACILITY It is important to start the facility design with an understanding of each process step involved with the manufacture of a sterile product. In this section, an overview is provided for some of the more mon process steps, including a description of the major equipment, material flows, and facility impacts. Nonactive Materials Nonactive materials are transported from the warehouse to the weigh/dispense area, where they are dispensed VOLUME 2: FACILITY DESIGN. STERILIZATION AND PROCESSING into containers under a hood with high efficiency particulate air (HEPA) filtration. The hoods used in the dispensing operation shall be designed for protection of the product and may also need to protect the operator from exposure to potentially hazardous materials used in the formulation process. The number of hoods, and type, will be determined by evaluating the number of weighing operations that must be performed, the size of the weighing operations, the patibility of materials that must be weighed, and any special ergonomic or personnel safely concerns. Materials that are not patible may need to be dispensed in separate hoods to prevent any crosscontamination concerns. Also, dispensing operations involving large bulk containers will require either a lift assist or pallet jack access to prevent operator injury, requiring the hood to be designed as a walkin typo. Hoods being designed for product protection typically recirculate air back to the dispensing room to reduce the HVAC consumption for the area. However, when weighing hazardous materials, the air from the hood may need to be captured and exhausted to the roof through some type of environmental control device. Hoods of this type are typically designed to be negatively pressurized with respect to the dispensing room. Containers may be either singleuse or reusable. Singleuse containers are disposable. Reusable containers are required to be tracked and controlled to prevent crosscontamination of clean and used containers. Prior to reuse, used containers should be brought to a parts preparation washroom for cleaning and then placed in controlled storage. Nonactive materials are dispensed into bags or plastic bottles and can be placed into plastic bins as part of preassembled kits. Preweighed nonactive materials are stored as kits and staged until they are ready to be transferred to the formulation area. Identifying labels should be placed on the containers. It is typical to provide a local WFI drop feeding a sink in the weigh/dispense area, with WFI temperature controlled by a local WFI drop cooler. The WFI drop is periodically flushed and sampled per SOP. WFI is used to prepare solutions of nonactive materials in bottles. This operation may bo performed with equipment such as a laboratory agitator. Bench scales are used for dispensing of smallerscale materials. Floor scales are used for larger quantities. Balances and measuring equipment should be of an appropriate range and precision. Active Materials Receipt/Storage Active materials, API or drug substance (DS), may be received in a wide variety of container types, in either frozen or liquid form, or as a solid. Careful consideration should be given to the form and container type, since this affects the storage, transport, preparation, and handling of API. The following list is provided to indicate the diversity of some mon examples. 1. Frozen in cryovessels, ranging in size from 50 to 300 L 2. Frozen in small containers, ranging in size from 1 to 20 L 3. As liquid in small containers, ranging in size from 1 to 20 L 4. As powder in canisters, ranging in size from 1 to 50 kg Weighing and dispensing can occur for either sterile or nonsterile material. It is remended that sterile material be dispensed in an isolator to prevent contamination. The isolator should be fitted with a rapid decon antechamber to facilitate the addition of product and containers to be dispensed.ASEPTIC MANUFACTURING FACILITY DESIGN 5 EQUIPMENT W ASH I COMPONENT PREP EQUIPMENT W ASH / COMPONENT PREP CONVENTIONAL t RABS OPERATIONS ISOLATOR TECHNOLOGY OPERATKNS Figure 1 {See color insert) Weigh and dispense. Nonsterile material should be protected by HEPA filtration during dispensing operations to prevent addition of particulate. Containers of API should not be opened for sampling prior to use in the formulation area. Therefore, it is remended that ail lot of API containe。 For foreign rights please contact: For reprint permissions please contact: Typeset by MPS Limited, A Macmillan Company Printed and bound in India We dedicate this work to those who have inspired us. To my parents Walter and Ruth Ludwig and my wife Sue Ludwig To my parents Hari and Pratiblm Nema and my wife Tina BuschNemaThis page intentionally left blankForeword I was a faculty member at the University of Tennessee and a colleague of Dr. Kenh Avis when he conceived, organized, and edited (along with . Lieberman and L. Lachman) the first edition of this book series that was published in 1984. It was so well received by the pharmaceutical science munity that an expanded threevolume second edition was published in 1992. Dr. Avis did not survive long enough to oversee a third edition, and it was questionable whether a third edition would ever be published until two of his graduate students, Drs. Nema and Ludwig, took it upon themselves to carry on Dr. Avis39。s negligence and to the fullest extent otherwise permitted by law, neither the publisher nor any person engaged or employed by the publisher shall be responsible or liable for any loss, injury or damage caused to any pers