SOP for Inspecting Aerosol Cans Before Packing

Department	Aerosol
SOP No.	SOP/Aerosol/091/2025
Supersedes	SOP/Aerosol/091/2022
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 inspecting aerosol cans before they are packed for distribution. The objective is to ensure that all aerosol cans meet the required quality standards for product safety, labeling, and functionality before they leave the production line. The inspection process helps prevent packaging defects, contamination, or labeling errors that could affect the quality of the product or the safety of the consumer.

2. Scope

This SOP applies to all aerosol cans manufactured at [Company Name] before they are packed for shipment. The procedure covers visual inspections, checking for defects, testing functionality, and ensuring proper labeling and sealing.

3. Responsibilities

• Production Team: Responsible for carrying out the initial inspections and notifying the QA team of any issues identified during the process.
• Quality Assurance (QA) Team: Responsible for performing final inspections, verifying compliance with product specifications, and ensuring that the cans meet regulatory and company quality standards before packing.
• Maintenance Team: Ensures that all inspection equipment used during the process is calibrated and maintained according to the company’s calibration schedule.
• Packaging Team: Responsible for ensuring that the packaging process only proceeds once the aerosol cans have passed all necessary inspections.

4. Accountability

The Manufacturing Manager is accountable for ensuring that aerosol cans undergo a proper inspection before packing. The overall compliance with this SOP is overseen by the Quality Assurance (QA) Manager.

5. Procedure

5.1. Visual Inspection of Aerosol Cans

1. The production team will perform an initial visual inspection of aerosol cans immediately after they are filled and sealed. The inspection should include:
   • Checking for any visible defects such as dents, scratches, or rust.
   • Inspecting the valve and actuator assembly for any damage or misalignment.
   • Ensuring that the can is properly sealed and that there are no leaks.
   • Confirming that the can’s exterior is clean, free from oil or other contaminants.
2. Any cans found with visible defects should be segregated and set aside for further evaluation. These cans should not proceed to the packing stage and should be documented in the Defective Can Log (Annexure-1).

5.2. Functional Testing of Aerosol Cans

1. QA will perform functional testing on a random sample of aerosol cans after they have been visually inspected. The tests should include:
   • Spray performance check: Ensuring that the aerosol dispenses correctly when the actuator is pressed.
   • Pressure test: Ensuring that the can is filled to the correct pressure and does not leak when subjected to standard pressure testing conditions.
   • Valve and actuator functionality: Ensuring that the valve opens and closes properly without sticking.
2. Any cans failing the functional tests should be segregated and the issue investigated. These cans should be documented in the Test Failure Log (Annexure-2) and investigated further to determine the root cause.

5.3. Labeling Inspection

1. The QA team will inspect the labeling on each aerosol can to ensure it is correct and conforms to company and regulatory standards. The inspection should include:
   • Ensuring that the correct product label is applied to each can.
   • Verifying that all required information is included on the label, such as product name, ingredients, usage instructions, batch number, expiration date, and safety warnings.
   • Ensuring that the label is applied correctly without wrinkles, smudges, or other defects.
2. If any labeling issues are identified, the affected cans should be segregated for re-labeling or disposal as per the company’s procedures.

5.4. Final Approval for Packing

1. Once the aerosol cans have passed the visual inspection, functional testing, and labeling inspection, the QA team will approve the batch for packing. The approval should be documented in the Finished Goods Approval Log (Annexure-3).
2. If any cans fail the inspection or testing process, they must not proceed to packing, and corrective actions must be taken. The failure should be documented and reported to the production team for resolution.
3. Once approved, the packing team may begin the packaging process, ensuring that only cans that have passed all inspection steps are included in the final packaged product.

5.5. Documentation and Record Keeping

1. All inspection activities, including visual inspections, functional tests, and labeling checks, must be documented in the relevant inspection logs, including:
   • Defective Can Log (Annexure-1)
   • Test Failure Log (Annexure-2)
   • Finished Goods Approval Log (Annexure-3)
2. Inspection records should be signed and dated by the personnel performing the inspection, and the records should be stored in the document management system for future reference and regulatory audits.
3. Records of defective cans and failure logs should be retained for a minimum of 3 years, or as required by regulatory guidelines.

6. Abbreviations

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

7. Documents

1. Defective Can Log (Annexure-1)
2. Test Failure Log (Annexure-2)
3. Finished Goods Approval 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: Defective Can Log

Can ID	Defect Type	Action Taken	Operator Name	Approval
CAN-001	Scratch on surface	Removed from line	Rajesh Patel	Approved

Annexure-2: Test Failure Log

Batch Number	Test Type	Test Result	Action Taken	Responsible Person
Batch-001	Pressure test	Fail	Re-calibrated pressure testing machine	Rajesh Patel

Annexure-3: Finished Goods Approval Log

Batch Number	Approval Date	Approving Authority	Comments
Batch-001	10/02/2025	Anjali Sharma	Approved for packing

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 inspection procedures	To comply with updated GMP regulations	Anjali Sharma	Page 1	[Ref Point]	Updated procedures