SOP for Preparing Lyophilized Formulations for Intravenous Use

Standard Operating Procedure for Preparing Lyophilized Formulations for Intravenous Use

1) Purpose

This SOP describes the process of preparing lyophilized formulations intended for intravenous (IV) administration, ensuring sterility, stability, and proper reconstitution characteristics.

2) Scope

This SOP applies to all personnel involved in the formulation, preparation, and testing of lyophilized products designed for intravenous administration.

3) Responsibilities

Formulation Scientists: Responsible for designing the IV lyophilized formulation and ensuring compatibility with reconstitution solutions.
Operators: Responsible for preparing the solution according to the Batch Manufacturing Record (BMR).
QA: Responsible for ensuring sterility, product stability, and proper documentation.

4) Procedure

4.1 Preparation of IV Lyophilized Formulation

4.1.1 Equipment Setup

4.1.1.1 Ensure that all equipment (e.g., mixers, sterilization units) is cleaned, sanitized, and calibrated before use.
4.1.1.2 Maintain aseptic conditions throughout the preparation process.

4.1.2 Solution Preparation

4.1.2.1 Weigh the required active ingredients and excipients using a calibrated balance according to the BMR.
4.1.2.2 Dissolve the active ingredients in a suitable solvent (e.g., Water for Injection) and stir until fully dissolved.

4.2 Filtration and Filling

4.2.1 Filtration

4.2.1.1 Filter the prepared solution using a sterile 0.22-micron filter to ensure sterility.

4.2.2 Filling and Lyophilization

4.2.2.1 Aseptically fill sterile vials with the filtered solution and freeze at -80°C before lyophilization.
4.2.2.2 Perform lyophilization according to the cycle parameters outlined in the BMR.

4.3 Reconstitution Testing

4.3.1 After lyophilization, test the reconstitution characteristics of the product by adding a suitable diluent (e.g., saline or dextrose solution) and monitoring the dissolution time.
4.3.2 Ensure that the solution reconstitutes fully, with no particulates, within the specified time frame.

4.4 Documentation

Record all steps, including solution preparation, filtration, filling, lyophilization parameters, and reconstitution test results, in the IV Lyophilized Formulations Logbook.

5) Abbreviations

BMR: Batch Manufacturing Record
WFI: Water for Injection

6) Documents

IV Lyophilized Formulations Logbook

7) References

Pharmacopoeial guidelines for IV drug products and reconstitution testing

8) SOP Version

Version 1.0

Annexure

IV Lyophilized Formulations Logbook Template


  
    Date
    Formulation Name
    Batch No.
    Reconstitution Time
    Volume Filled
    Operator Initials
    QA Verification
  
  
    DD/MM/YYYY
    Formulation Name
    Batch Number
    Reconstitution Time (minutes)
    Volume in mL
    Operator Name
    QA Initials

Date	Formulation Name	Batch No.	Reconstitution Time	Volume Filled	Operator Initials	QA Verification
DD/MM/YYYY	Formulation Name	Batch Number	Reconstitution Time (minutes)	Volume in mL	Operator Name	QA Initials