Creams: SOP for Operating Vacuum Pumps in Cream Processing – V 2.0

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Creams: SOP for Operating Vacuum Pumps in Cream Processing – V 2.0

Standard Operating Procedure for Operating Vacuum Pumps in Cream Processing

Department Creams
SOP No. SOP/CRM/062/2025
Supersedes SOP/CRM/062/2022
Page No. Page 1 of 5
Issue Date 22/12/2025
Effective Date 27/12/2025
Review Date 22/12/2026

1. Purpose

The purpose of this Standard Operating Procedure (SOP) is to outline the proper operation of vacuum pumps used in the processing of creams. Vacuum pumps are critical in cream production, especially in the homogenization and degassing stages, to ensure proper texture, stability, and consistency. This SOP ensures that vacuum pumps are operated safely, efficiently, and in compliance with GMP standards.

2. Scope

This SOP applies to the operation of all vacuum pumps used in the cream manufacturing process within the Creams Department. It includes procedures for starting, operating, and shutting down vacuum pumps, as well as for routine maintenance and troubleshooting.

3. Responsibilities

  • Production Team: Responsible for operating the vacuum pumps during the production process, ensuring that they are used correctly, and documenting their operation as per this SOP.
  • Maintenance Team: Responsible for the routine maintenance and calibration of the vacuum pumps, ensuring that they are functioning optimally and are free from defects.
  • Quality Control (QC): Responsible for monitoring and verifying that the vacuum pumping process is carried out correctly, ensuring product quality standards are met.
  • Quality Assurance (QA): Ensures that the vacuum pump operation complies with this SOP and GMP guidelines, and reviews operational records to confirm proper documentation.

4. Accountability

The Head of Creams Manufacturing is responsible for ensuring that vacuum pump operation follows this SOP. The QA Manager is accountable for reviewing the operation and maintenance logs, ensuring compliance, and approving any deviations or corrective actions.

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5. Procedure

5.1 Pre-Operation Checks

  1. Before operating the vacuum pump, ensure that the equipment has been thoroughly inspected for any signs of wear, damage, or contamination.
  2. Verify that all necessary components, such as hoses, connectors, and valves, are securely attached and in good condition.
  3. Ensure that the vacuum pump’s power supply is connected and that it is calibrated according to the manufacturer’s specifications.
  4. Check that the vacuum pump is set up according to the process requirements, including appropriate vacuum pressure and flow rate.

5.2 Starting the Vacuum Pump

  1. Turn on the vacuum pump by following the manufacturer’s instructions. Ensure that the pump starts smoothly without any unusual noise or vibration.
  2. Gradually increase the vacuum pressure to the desired level, ensuring that the vacuum pump operates within the specified pressure range.
  3. Monitor the pressure gauge and other indicators to verify that the vacuum pump is operating correctly.
  4. If the vacuum pump fails to reach the desired vacuum level, stop the operation immediately and investigate potential issues such as blockages, leaks, or equipment malfunction.

5.3 Monitoring the Vacuum Pump Operation

  1. Continuously monitor the operation of the vacuum pump during the production process. Check the vacuum levels regularly to ensure that they remain consistent and within the specified range.
  2. Listen for unusual sounds or vibrations that could indicate a malfunction, such as bearing failure or impeller blockages.
  3. Monitor the pump’s temperature and pressure readings to ensure that it is operating efficiently and safely.
  4. If the vacuum pump encounters any issues, such as fluctuating pressure or overheating, stop the process immediately and troubleshoot the problem with the assistance of the maintenance team.
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5.4 Shutting Down the Vacuum Pump

  1. To stop the vacuum pump, gradually reduce the vacuum pressure to zero and turn off the power supply. Ensure that the system returns to a neutral state before performing any maintenance or moving the equipment.
  2. If the vacuum pump is part of an automated system, follow the shutdown procedure provided by the system’s control panel.
  3. Once the vacuum pump has stopped, ensure that all hoses and connectors are securely disconnected to prevent contamination or leaks.

5.5 Routine Maintenance

  1. Perform routine maintenance checks as per the manufacturer’s guidelines, including lubricating moving parts, checking seals and valves, and inspecting hoses for signs of wear or damage.
  2. Clean the vacuum pump regularly to remove any product residues that could cause contamination or affect performance.
  3. Inspect the filters and replace them as needed to ensure optimal pump performance.
  4. Document all maintenance activities in the equipment maintenance log, including the date, type of maintenance performed, and any issues found during inspection.

5.6 Troubleshooting

  1. If the vacuum pump is not operating correctly, troubleshoot by checking for the following common issues:

    • Vacuum leaks in hoses or connections
    • Clogged or damaged filters
    • Incorrect pressure settings
    • Power supply issues
  2. If a problem cannot be resolved quickly, stop the operation and contact the maintenance team for further investigation and repair.
  3. Document any issues encountered and the corrective actions taken in the deviation report (Annexure-1).

5.7 Documentation

  1. Complete the Vacuum Pump Operation Log (Annexure-2) for each production cycle, documenting start-up and shut-down times, operational parameters, and any issues encountered.
  2. Include any maintenance or troubleshooting activities performed in the equipment maintenance log.
  3. Ensure that all records are signed by the operator and reviewed by the QA team to verify compliance with this SOP.
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5.8 Final Approval

  1. The QA team must review the operation log and maintenance records to ensure that the vacuum pump was operated correctly and that there were no deviations from the SOP.
  2. Once the review is complete, the vacuum pump is approved for use in subsequent production cycles.

6. Abbreviations

  • QC: Quality Control
  • QA: Quality Assurance
  • GMP: Good Manufacturing Practices
  • PPE: Personal Protective Equipment

7. Documents

  1. Vacuum Pump Operation Log (Annexure-2)
  2. Deviation Report Form (Annexure-1)

8. References

  • Good Manufacturing Practices (GMP) Guidelines – 21 CFR Part 211
  • International Conference on Harmonisation (ICH) Q7 – Good Manufacturing Practice for Active Pharmaceutical Ingredients
  • FDA Guidelines for Cosmetics Manufacturing

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Deviation Report Form

Deviation Description Time Batch Number Operator Immediate Action
Vacuum fluctuation 08:45 AM 12345 John Doe Notified maintenance

Annexure-2: Vacuum Pump Operation Log

Time Vacuum Pressure Operator Comments
08:00 AM 50 mbar Jane Smith No issues

Revision History:

Revision Date Revision No. Revision Details Reason for Revision Approved By
01/03/2024 1.0 Initial Version New SOP Creation QA Head
01/03/2025 2.0 Format Revision and Updates Standardization of Document QA Head
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