SOP for Lyophilization of Nasal Powders




SOP for Lyophilization of Nasal Powders



Standard Operating Procedure for Lyophilization of Nasal Powders

1) Purpose

The purpose of this SOP is to outline the procedures for lyophilizing nasal powder formulations. Lyophilization (freeze-drying) ensures the stability and shelf life of temperature-sensitive or moisture-sensitive ingredients by removing moisture under low temperature and pressure.

2) Scope

This SOP applies to all personnel involved in the preparation, lyophilization, and packaging of nasal powders at [Company Name].

3) Responsibilities

  • Operators: Responsible for operating lyophilization equipment, ensuring correct freeze-drying conditions.
  • Quality Assurance (QA): Ensures that the lyophilized product meets quality and stability specifications.
  • Maintenance Team: Responsible for maintaining and calibrating lyophilization equipment.

4) Procedure

4.1 Preparation of Formulation

4.1.1 Ingredient Selection

  • Select APIs and excipients suitable for freeze-drying. Ensure that the ingredients maintain stability under freezing conditions.

4.1.2 Weighing and Mixing

  • Weigh the API and excipients accurately using a calibrated balance. Ensure the quantities fall within ±2% of the target weight.
  • Mix the ingredients to create a uniform blend. Record the mixing parameters, including speed and time, in the Batch Manufacturing Record (BMR).

4.2 Lyophilization Process

4.2.1 Freezing the Formulation

  • Transfer the blended formulation into pre-sterilized trays. Place the
trays in a pre-cooled chamber at -40°C or lower, depending on the formulation’s freezing point.
  • Monitor the freezing process until the formulation is completely frozen. Record the temperature and freezing duration in the BMR.
  • 4.2.2 Primary Drying

    • Initiate primary drying by reducing the pressure in the lyophilizer to a vacuum of less than 100 millitorr. Slowly raise the temperature to sublimate the frozen water from the formulation.
    • Monitor the chamber pressure and shelf temperature throughout the process to ensure effective sublimation. Record all parameters in the BMR.

    4.2.3 Secondary Drying

    • After the primary drying phase, increase the temperature to remove any bound water. Maintain the vacuum throughout the process.
    • Continue secondary drying until the residual moisture content falls below the target level (typically less than 1%). Record the final moisture content in the BMR.

    4.3 Post-Lyophilization Testing

    4.3.1 Moisture Content Testing

    • Test the moisture content of the lyophilized powder using the Karl Fischer method or another validated method. Ensure that the moisture content falls within the acceptable range for nasal powders (typically less than 2%).
    • Record the moisture content results in the moisture content log.

    4.3.2 Particle Size Testing

    • Perform particle size analysis on the lyophilized powder using laser diffraction or another suitable method. Ensure the particle size is within the target range for nasal delivery (typically 1-10 microns).
    • Record the particle size distribution in the particle size testing log.

    4.4 Packaging

    4.4.1 Filling Process

    • Fill the lyophilized nasal powder into pre-sterilized containers using a powder filling machine. Ensure that the powder is filled in an environment with low humidity to prevent moisture absorption.
    • Record the fill weight for 10 random samples, ensuring that the fill volume is within ±5% of the target weight. Document the results in the BMR.

    4.4.2 Sealing and Packaging

    • Seal the filled containers with pre-sterilized caps or nozzles. Store the containers in a moisture-controlled environment (e.g., desiccated packaging) to maintain the stability of the lyophilized powder.
    • Label the containers with batch numbers, expiration dates, and storage instructions.

    4.5 Quality Control Testing

    4.5.1 Stability Testing

    • Conduct stability testing on the lyophilized powder under different temperature and humidity conditions to ensure long-term stability.
    • Record the stability testing results in the stability testing log.

    4.6 Documentation

    • Document all steps of the lyophilization process, including freezing, primary drying, secondary drying, and post-lyophilization testing, in the BMR.
    • Ensure QA reviews and approves all documentation before the product is released for distribution.

    4.7 Equipment Cleaning and Calibration

    4.7.1 Equipment Calibration

    • Calibrate all equipment used in the lyophilization process, including lyophilizers, balances, and particle size analyzers, according to the calibration schedule.
    • Record calibration data in the calibration log.

    4.7.2 Cleaning Equipment

    • Clean all equipment used in the lyophilization process according to the cleaning validation protocol. Document the cleaning process in the cleaning log.

    5) Abbreviations, if any

    • API: Active Pharmaceutical Ingredient
    • QA: Quality Assurance
    • BMR: Batch Manufacturing Record

    6) Documents, if any

    • Batch Manufacturing Record (BMR)
    • Moisture Content Log
    • Particle Size Testing Log
    • Stability Testing Log
    • Calibration Log
    • Cleaning Log

    7) References, if any

    • ICH Q1A – Stability Testing Guidelines
    • FDA Guidance for Nasal Drug Products

    8) SOP Version

    Version 1.0

    Annexure

    1. Moisture Content Log Template

    Date Formulation Moisture Content (%) Test Method Operator Initials QA Approval
    DD/MM/YYYY Formulation Name Moisture Content Method Operator Name QA Name
               

    2. Particle Size Testing Log Template

    Date Formulation Particle Size (µm) Test Method Operator Initials QA Approval
    DD/MM/YYYY Formulation Name Particle Size Method Operator Name QA Name
               

    3. Calibration Log Template

    Date Equipment ID Calibration Procedure Calibration Results Operator Initials QA Approval
    DD/MM/YYYY Equipment Name/ID Procedure Pass/Fail Operator Name QA Name
               

    4. Stability Testing Log Template

    Date Formulation Storage Conditions Time Interval Stability Results Operator Initials QA Approval
    DD/MM/YYYY Formulation Name Temperature and Humidity 1 month, 3 months, etc. Pass/Fail Operator Name QA Name
               


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