To achieve the goal of a manufactured sterile product of exceptionally high quality, many functional production areas are
involved: warehousing or procurement; compounding (formulation); materials (containers, closures, equipment) preparation;
filtration and sterile receiving; aseptic filling; stoppering; lyophilization (if warranted); and packaging, labeling, and quarantine.
The extra requirements for the aseptic area are designed to provide an environment where a sterile fluid may be exposed to the
environment for a brief period during subdivision from a bulk
container to individual-dose containers, without becoming contaminated. Contaminants, such as dust, lint, and other particles
and micro-organisms, are found floating in the air, lying on counters and other surfaces, attached to clothing and body surfaces of
personnel, concentrated in the exhaled breath of personnel, and
deposited on the floor. The design and control of an aseptic area
is directed toward reducing the presence of these contaminants,
so they are no longer a hazard to aseptic filling.
Although the aseptic area must be adjacent to support areas,
so an efficient flow of components may be achieved, barriers
must be provided to minimize ingress of contaminants to the
critical aseptic area. Such barriers may consist of a variety of
forms, including sealed walls, manual or automatic doors, airlock pass-throughs, ports of various types, or plastic curtains.
Figure 26-6 shows an example of a floor plan for a clinical supply production facility (selected as an example of a small-scale,
noncomplex facility) in which the two fill rooms and the staging
area constitute the walled critical aseptic area, access to which
is only by means of pass-through airlocks. Adjacent support areas (rooms) consist of glass preparation, equipment wash, capping, manufacturing (compounding), and various storage areas.
Figure 26-7 shows an example of a Class 100/Grade A small
scale filling room with operators properly gowned and practicing good aseptic techniques
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