provides a continuous surface free from all holes or crevices.
All such surfaces can be washed at regular intervals to keep
them thoroughly clean. These areas should be exhausted adequately, so the heat and humidity are removed for the comfort
of personnel. Precautions must be taken to prevent the accumulation of dirt and the growth of micro-organisms due to the
high humidity and heat. In this area, preparation for the filling
operation, such as cleaning and assembling equipment, is undertaken. Adequate sink and counter space must be provided.
This area must be cleanable, and the microbial load must be
monitored and controlled. Precautions must also be taken to
prevent deposition of particles or other contaminants on clean
containers and equipment, until they have been properly boxed
or wrapped preparatory to sterilization and depyrogenation.
Compounding Area—The formula is compounded in this
area. Although it is not essential that this area be aseptic, control of micro-organisms and particulates should be more stringent than in the materials support area. For example, means
may need provided to control dust generated from weighing and
compounding operations. Cabinets and counters should, preferably, be constructed of stainless steel. They should fit snugly
to walls and other furniture, so there are no catch areas dirt can
accumulate. The ceiling, walls, and floor should be similar to
those for the materials support area.
Aseptic Area—The aseptic area requires construction features designed for maximum microbial and particulate control.
The ceiling, walls, and floor must be sealed, so they may be
washed and sanitized with a disinfectant, as needed. All counters should be constructed of stainless steel and hung from the
wall, so there are no legs to accumulate dirt, where they rest
on the floor. All light fixtures, utility service lines, and ventilation fixtures should be recessed in the walls or ceiling to eliminate ledges, joints, and other locations for the accumulation of
dust and dirt. As much as possible, tanks containing the compounded product should remain outside the aseptic filling area,
with the product fed into the area through hose lines. Proper
sanitization is required, if the tanks must be moved in. Large
mechanical equipment located in the aseptic area should be
housed as completely as possible within a stainless steel cabinet, to seal the operating parts and their dirt-producing tendencies from the aseptic environment. Further, all such equipment
parts should be located below the filling line. Mechanical parts
that will contact the parenteral product should be demountable, so they can be cleaned and sterilized.
Personnel entering the aseptic area should enter only
through an airlock. They should be attired in sterile coveralls
with sterile hats, masks, goggles, foot covers, and double gloves.
Movement within the room should be minimal, and in-and-out
movement rigidly restricted during a filling procedure. The requirements for room preparation and the personnel may be relaxed, if the product is to be sterilized terminally in a sealed
container. Some are convinced, however, it is better to have one
standard procedure meeting the most rigid requirements.
Isolation (Barrier) Technology—Isolator (or barrier) technology has long been used in the pharmaceutical industry and
ranges from simple screens to restricted access barriers (RABS)
to full isolation systems, all designed to isolate aseptic operations from personnel and the surrounding environment. Sterility tests are now almost exclusively conducted within isolators.
A false-positive sterility test is practically unheard of these days,
such that, if a positive test does occur, it likely is a true contamination, not as a result of contamination introduced during the
test. Isolation technology in various formats has been adapted
to automated, large-scale, aseptic filling operations.
24An example of a sterility test isolator is shown in Figure 26-10, and an
example of a filling operation within an isolator is shown in Figure 26-11. The sealed enclosures are presterilized, usually with
peracetic acid, hydrogen peroxide vapor, or steam. Sterile supplies are introduced from sterilizable movable modules through
uniquely engineered transfer ports or directly from attached
sterilizers, including autoclaves and hot-air sterilizing tunnels.
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