SOP Guide for Pharma

Tablets: SOP for Continuous Tablet Manufacturing Process – V 2.0

Auditor

Tablets: SOP for Continuous Tablet Manufacturing Process – V 2.0

Standard Operating Procedure for Continuous Tablet Manufacturing Process

Department Tablet
SOP No. SOP/TAB/030/2025
Supersedes SOP/TAB/030/2022
Page No. Page 1 of 8
Issue Date 08/07/2025
Effective Date 13/07/2025
Review Date 08/07/2026

1. Purpose

This SOP outlines the procedures for the continuous tablet manufacturing process. The goal is to ensure efficient, consistent, and high-quality tablet production with minimal downtime and waste. Continuous manufacturing enables real-time monitoring and control of the production parameters.

2. Scope

This SOP applies to the continuous tablet manufacturing process, including formulation, compression, coating, and packaging stages. It covers the equipment setup, monitoring, and control systems used in continuous tablet production.

3. Responsibilities

4. Accountability

The Production Manager is accountable for ensuring the correct implementation of the continuous tablet manufacturing process and compliance with this SOP. The QA Manager is responsible for reviewing batch records and ensuring the process meets regulatory and internal standards.

5. Procedure

5.1 Pre-Operation Setup

  1. Ensure that the continuous tablet manufacturing line, including all equipment such as granulators, tablet presses, and coating machines, is properly set up and calibrated.
  2. Verify that all required raw materials, including APIs, excipients, and coating solutions, are available and meet the required specifications.
  3. Confirm that all process parameters for the continuous line (e.g., feed rate, compression speed, tablet weight, coating parameters) are set according to the product specifications.
  4. Ensure that the real-time monitoring systems, including weight checkers, moisture analyzers, and coating thickness gauges, are operational.
  5. Ensure that the dust collection and air filtration systems are properly set up and functional to prevent contamination and maintain clean air quality in the manufacturing area.
See also  Tablets: SOP for Anti-Dusting Measures in Tablet Compression - V 2.0

5.2 Continuous Formulation and Granulation

  1. Feed the raw materials into the continuous granulator at the specified feed rate, ensuring proper mixing and granule formation.
  2. Monitor the moisture content, particle size distribution, and uniformity of the granules in real-time using in-line sensors.
  3. Adjust the granulator speed and binder solution flow rate based on real-time feedback to achieve the desired granule quality.
  4. Record all in-process data, including moisture content, granule size, and mixing time, in the batch record (Annexure-1).

5.3 Tablet Compression

  1. Transfer the granules to the tablet press system for continuous compression. Ensure that the tablet press is operating within the desired compression force range, tablet weight, and thickness parameters.
  2. Monitor tablet weight, hardness, and friability in real-time to ensure uniformity and consistency of the tablets being produced.
  3. Adjust the tablet press settings (e.g., compression speed, die fill level, tablet hardness) to maintain the required tablet specifications.
  4. If deviations from the target specifications are detected, make immediate adjustments to the compression parameters and document any corrective actions taken in the batch record.
  5. Ensure that all tablet presses are equipped with automated tablet ejection and rejection systems to remove defective tablets from the production line.

5.4 Tablet Coating (if applicable)

  1. Transfer the compressed tablets to the continuous coating system. Ensure that the coating pan is set to the correct speed, air flow, and spray rate for the desired coating thickness.
  2. Monitor the tablet coating thickness in real-time using coating thickness gauges to ensure uniform application.
  3. Adjust the spray rate, temperature, and tablet pan speed as needed to maintain the required coating thickness and avoid over-coating or under-coating.
  4. Ensure that the coating solution is applied uniformly across all tablets and that the coating process is completed without defects (e.g., peeling, uneven coating).
  5. Document the coating process parameters, including coating solution concentration, tablet temperature, and coating thickness, in the batch record (Annexure-2).
See also  Tablets: SOP for Friability Testing for Sugar-Coated Tablets - V 2.0

5.5 Packaging

  1. Once the tablets have passed all quality checks (e.g., weight variation, hardness, coating uniformity), transfer them to the packaging station.
  2. Ensure that the packaging machine is set to the correct packaging format (e.g., blister packs, bottles, etc.) and that the packaging materials are properly aligned and free of defects.
  3. Monitor the packaging process to ensure that tablets are placed into packaging units without damage and that seals are intact.
  4. Ensure that the appropriate labeling and batch information are applied to the packaging as per the batch record and regulatory requirements.

5.6 Continuous Monitoring and Adjustments

  1. Monitor the entire continuous manufacturing process in real-time using automated systems to detect any variations in critical process parameters (e.g., tablet weight, hardness, coating thickness, granule size, moisture content).
  2. If deviations are detected, make immediate adjustments to the process parameters and document the changes in the batch record (Annexure-3).
  3. Ensure that all alarms and alerts from the continuous monitoring system are responded to promptly to prevent production delays or defects.

5.7 Documentation and Record-Keeping

  1. Document all process parameters, including formulation settings, compression settings, coating parameters, and packaging data, in the batch record for traceability and quality control (Annexure-1, Annexure-2, Annexure-3).
  2. Ensure that all deviations from the target specifications are recorded along with corrective actions and approved by the responsible personnel.
  3. Ensure that all records are reviewed by QA personnel and that the records are stored in compliance with regulatory requirements.

5.8 Post-Production Cleaning and Equipment Shutdown

  1. After completing the production run, shut down the continuous manufacturing line according to the equipment shutdown SOP.
  2. Clean all equipment, including the granulator, tablet press, and coating machine, according to the cleaning SOP to prevent cross-contamination between batches.
  3. Document the cleaning activities in the cleaning log (Annexure-4) and ensure that all equipment is ready for the next production cycle.
See also  Tablets: SOP for Setup and Validation of Semi-Automatic Tablet Press - V 2.0

6. Abbreviations

7. Documents

  1. Batch Record (Annexure-1)
  2. Coating Process Log (Annexure-2)
  3. Production Monitoring Log (Annexure-3)
  4. Cleaning Log (Annexure-4)

8. References

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Batch Record

Batch Number Tablet Type Tooling Condition Cleaning Date Remarks
Batch 001 Tablet A Good 01/06/2025 Inspection and cleaning completed
Batch 002 Tablet B Minor Wear 02/06/2025 Replaced damaged punch

Annexure-2: Coating Process Log

Coating Start Time Coating Solution Used Tablet Temperature Coating Thickness Remarks
10:00 AM Coating Solution A 30°C 0.2mm Completed successfully
2:00 PM Coating Solution B 32°C 0.25mm Adjustment made to spray rate

Annexure-3: Production Monitoring Log

Parameter Target Value Actual Value Deviation Corrective Action
Tablet Weight 250 mg 248 mg -2 mg Adjusted compression speed
Tablet Hardness 5 kg 5.2 kg +0.2 kg Reduced compression force

Annexure-4: Cleaning Log

Cleaning Date Equipment Cleaning Type Performed By Remarks
01/06/2025 Granulator Routine Cleaning John Doe Performed as per SOP
02/06/2025 Tablet Press Routine Cleaning Jane Smith No issues found

Revision History:

Revision Date Revision No. Revision Details Reason for Revision Approved By
01/01/2024 1.0 Initial Version New SOP Creation QA Head
01/02/2025 2.0 Updated Continuous Line Parameters Optimization of Process Parameters QA Head
Exit mobile version