Aerosol: SOP for Conducting Valve Functionality Tests – V 2.0

Posted on By

Aerosol: SOP for Conducting Valve Functionality Tests – V 2.0

SOP for Conducting Valve Functionality Tests

Department Aerosol
SOP No. SOP/Aerosol/064/2025
Supersedes SOP/Aerosol/064/2022
Page No. Page 1 of Y
Issue Date 06/02/2025
Effective Date 16/02/2025
Review Date 06/02/2028

1. Purpose

This Standard Operating Procedure (SOP) outlines the process for conducting valve functionality tests on aerosol products. The objective is to ensure that the aerosol valves are functioning properly, allowing for consistent spray delivery without leakage or malfunction. The proper functioning of the valve is crucial to achieving the desired performance, safety, and quality of aerosol products. Regular valve testing helps to maintain product integrity and comply with Good Manufacturing Practices (GMP).

2. Scope

This SOP applies to all aerosol valves used in the production of aerosol products at [Company Name]. It covers the procedure for testing the functionality of aerosol valves during production and before final packaging to ensure they are working as intended.

3. Responsibilities

  • Production Team: Responsible for conducting valve functionality tests and ensuring that any defective valves are identified and replaced before the product moves forward in the production process.
  • Quality Control (QC) Team: Responsible for overseeing the valve functionality testing process, ensuring compliance with this SOP, and reviewing the test results to verify that valves meet the required specifications.
  • Maintenance Team: Responsible for ensuring that testing equipment used for valve functionality checks is calibrated, maintained, and functioning properly.
  • Health and Safety Officer: Ensures that safety protocols are followed during the valve testing process, especially regarding the handling of pressurized cans and propellants.

4. Accountability

The Manufacturing Manager is accountable for ensuring that this SOP is followed and that aerosol valves are tested for functionality before final packaging. The overall compliance with this SOP is overseen by the Quality Assurance (QA) Manager.

See also  Aerosol: SOP for Starting and Stopping Aerosol Filling Machines - V 2.0

5. Procedure

5.1. Pre-Test Preparation

  1. Ensure that the aerosol cans are fully filled and sealed before testing the valve functionality.
  2. Prepare the necessary testing equipment, including:
    • Valve functionality testing apparatus (e.g., spray test rig or manual spray test device)
    • Stopwatch or timer for measuring spray duration
    • Compressed air or propellant gas for pressurizing the aerosol can
    • PPE, including gloves and goggles, for safety during testing
  3. Inspect the valve testing apparatus to ensure it is clean, calibrated, and properly assembled for the tests.
  4. Ensure that the testing area is clear of any obstructions or contamination that may affect the test results.

5.2. Conducting the Valve Functionality Test

  1. Position the aerosol can securely in the valve testing apparatus, ensuring that the valve is aligned correctly for testing.
  2. Apply pressure to the aerosol can using compressed air or propellant, depending on the test method. This will activate the valve and simulate normal operation.
  3. For the spray test:
    • Press the valve for a set time (e.g., 5 seconds) and observe the spray pattern.
    • Ensure that the spray is consistent, without sputtering, blockage, or leakage around the valve area.
    • Measure the spray volume or weight dispensed within the specified time frame and compare it to the product specifications.
  4. For the leak test:
    • Hold the aerosol can in an upright position and observe the valve area for any signs of leakage or hissing sounds when the can is activated.
    • Ensure that there is no leakage from the valve, both during activation and while the can is stationary.
  5. Repeat the valve functionality test for a sample of aerosol cans to ensure consistent performance across multiple units.
See also  Aerosol: SOP for Bulk Solution Preparation in Aerosols - V 2.0

5.3. Post-Test Actions

  1. For cans that pass the test, proceed with the next steps in the production process, ensuring that all valves are functioning properly and meeting product specifications.
  2. If any can fails the valve functionality test (e.g., spray pattern is inconsistent, leakage detected), remove the defective can from the production line for further inspection or disposal.
  3. Document the results of the valve functionality tests, including the test date, can ID, operator name, test results, and any corrective actions taken, in the Valve Functionality Test Log (Annexure-1).

5.4. Calibration and Maintenance of Equipment

  1. Regularly calibrate the valve functionality testing apparatus according to the manufacturer’s guidelines to ensure accurate measurements.
  2. Perform routine maintenance on the testing equipment, including cleaning, checking for wear, and replacing parts that may affect the accuracy of the test.
  3. Document all calibration and maintenance activities in the Equipment Calibration Log (Annexure-2) and the Equipment Maintenance Log (Annexure-3).

5.5. Documentation and Record-Keeping

  1. Document all valve functionality test results in the Valve Functionality Test Log (Annexure-1), including details such as the can ID, test date, operator name, and any deviations or issues found during testing.
  2. Ensure that the results are reviewed and approved by the QC team to confirm that the aerosol product meets the required valve performance specifications.
  3. Maintain records of valve functionality testing according to the company’s document retention policy, ensuring that they are available for future reference and audits.

5.6. Safety and Environmental Considerations

  1. Ensure that all personnel involved in valve functionality testing wear the appropriate PPE, including gloves, goggles, and protective aprons, to prevent exposure to propellants or other chemicals.
  2. Perform all testing in a well-ventilated area or fume hood to prevent the buildup of propellant vapors or other potentially hazardous fumes.
  3. Dispose of any waste materials, such as defective cans or contaminated equipment, according to the company’s waste disposal procedures and environmental regulations.
See also  Aerosol: SOP for Gas Filling in Aerosol Cans - V 2.0

6. Abbreviations

  • GMP: Good Manufacturing Practice
  • QC: Quality Control
  • PPE: Personal Protective Equipment
  • SOP: Standard Operating Procedure

7. Documents

  1. Valve Functionality Test Log (Annexure-1)
  2. Equipment Calibration Log (Annexure-2)
  3. Equipment Maintenance Log (Annexure-3)

8. References

This SOP is based on the following regulatory guidelines and industry standards:

  • Good Manufacturing Practice (GMP) Guidelines
  • FDA Code of Federal Regulations (CFR) Title 21, Part 211
  • ISO 9001:2015 – Quality Management Systems

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Valve Functionality Test Log

Can ID Test Date Test Type Result Operator Name Remarks
C-12345 06/02/2025 Spray Test Pass Rajesh Patel No issues found

Annexure-2: Equipment Calibration Log

Equipment ID Calibration Date Calibration Results Operator Name Remarks
VAL-001 06/02/2025 Pass Rajesh Patel No adjustments required

Annexure-3: Equipment Maintenance Log

Equipment ID Maintenance Date Tasks Performed Operator Name Remarks
VAL-001 06/02/2025 Cleaned and calibrated Rajesh Patel No issues found

12. Revision History:

Revision Date Revision No. Revision Details Reason for Revision Approved By Page No. Ref. Point No. Details of Revision
01/01/2024 V 1.0 Initial Release First Issue Anjali Sharma Page 1 [Ref Point] First Release
01/01/2025 V 2.0 Updated valve functionality testing procedure To comply with updated GMP regulations Anjali Sharma Page 1 [Ref Point] Updated procedures
Aerosols V 2.0 Tags:, , , , , , , , , , , , , , , , , , , , , , , , , , , , ,