heating ventilation and air conditioning (hvac) part i: introduction and overview air handling...
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HeatingVentilation andAir Conditioning (HVAC)
Part I: Introduction and overview
Air Handling Systems
Supplementary Training Modules on GMP
Module3: Part 1: Introduction and overview Slide 1 of 20 WHO - EDM
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Module 3, Part 1: Introduction and overview Slide 2 of 20 WHO - EDM
Air Handling Systems
Objectives
To understand:
1. The need and reason for pharmaceutical
air handling systems
1. The technical requirements for air handling systems
2. Different types of air handling systems
3. Qualification and monitoring requirements
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Module 3, Part 1: Introduction and overview Slide 3 of 20 WHO - EDM
Air Handling Systems
Factors that contribute to quality products:1. Starting materials and packaging materials
2. Validated processes
3. Personnel
4. Procedures
5. Equipment
6. Design and quality of premises
7. Manufacturing environment
Inadequacies in the above factors will lead to sub-standard products.
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Module 3, Part 1: Introduction and overview Slide 4 of 20 WHO - EDM
Air Handling Systems
Factors contributing to quality products
Starting materials
Personnel
Procedures
Validated processes
Equipment
Premises
Environment
Packing materials
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Module 3, Part 1: Introduction and overview Slide 5 of 20 WHO - EDM
Air Handling Systems
The manufacturing environment is critical for product quality Light
Temperature
Humidity
Air movement
Microbial contamination
Particulate contamination
Uncontrolled environment can lead to product degradation
product contamination
loss of product and profit
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Module 3, Part 1: Introduction and overview Slide 6 of 20 WHO - EDM
Air Handling Systems
What are contaminants ?Contaminants are
1. Products or substances other than product manufactured
2. Foreign products
3. Particulate matter
4. Micro-organisms
5. Endotoxins (degraded micro-organisms)
Cross-contamination is a particular case of contamination
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Module 3, Part 1: Introduction and overview Slide 7 of 20 WHO - EDM
Air Handling Systems
Cross-Contamination (1)
What is Cross-Contamination ?
Definition of Cross-Contamination:
Contamination of a starting material, intermediate product, or finished product with another starting material or product during production. (WHO)
Annex 1, Glossary
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Air Handling Systems
Cross-Contamination (2)From where does Cross-Contamination originate?
1. Poorly designed air handling systems and dust extraction systems
2. Poorly operated and maintained air handling systems and dust extraction systems
3. Inadequate procedures for personnel and equipment
4. Insufficiently cleaned equipment
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Module 3, Part 1: Introduction and overview Slide 9 of 20 WHO - EDM
Air Handling Systems
Contamination
Contaminant from
EnvironmentOperators
Contaminant from
Equipment
CrossContamination
Productfrom
EnvironmentOperators
Productfrom
Equipment
Cross-Contamination ( 3 )
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Module 3, Part 1: Introduction and overview Slide 10 of 20 WHO - EDM
Air Handling Systems
Cross-Contamination (4)
Cross-contamination can be minimized by:
1. Personnel procedures
2. Adequate premises
3. Use of closed production systems
4. Adequate, validated cleaning procedures
5. Appropriate levels of protection of product
6. Correct air pressure cascade
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Module 3, Part 1: Introduction and overview Slide 11 of 20 WHO - EDM
Air Handling Systems
Level of Protection Concept
Defines environmental requirements
Helps prevent contamination and cross-contamination
Allows production under optimal hygiene conditions
Takes into account
product sensitivity to contamination therapeutic risk
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Module 3, Part 1: Introduction and overview Slide 12 of 20 WHO - EDM
Air Handling Systems
Therapeutic risks
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Air Handling Systems
Levels of Protection
Parameters to be defined:
1. Air cleanliness requirements (filters type and position, air changes, air flow patterns, pressure differentials, contamination levels by particulate matter and micro-organisms)
2. Personnel and material transfer methods
3. Permitted operations
4. Building design and finishesAnnex 1, 17.3, 17.4
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Module 3, Part 1: Introduction and overview Slide 14 of 20 WHO - EDM
Air Handling Systems
Levels of Protection
Types of Cleanroom Classes
International
WHO A, B, C, D
National
EC, PIC/S, TGA, etc. : A, B, C, D US FDA : critical and controlled ISPE: level 1, 2 or 3 or cleanroom
class
Companies : various others Annex 1, 17.3, 17.4
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Module 3, Part 1: Introduction and overview Slide 15 of 20 WHO - EDM
Air Handling Systems
Levels of Protection
All operations within a pharmaceutical facilility must be correlated to well-defined cleanroom classes, and can be included in a hygiene concept.
Example:
etc.
XFilling for aseptic process
XFilling for terminal sterilisation
XDepyrogenisation of containers
XXXPreparation of solutions for aseptic filling
XPreparation of solution for terminal sterilisation
XWashing of containers
DCBA
Annex 1, 17.3, 17.4, 17.5
Cleanroom Class
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Module 3, Part 1: Introduction and overview Slide 16 of 20 WHO - EDM
Air Handling Systems
Levels of ProtectionBased on the cleanroom class requirements, various Levels of Protection have to be created, including: Correlation between process operations and cleanroom classes
Type of operation permitted in each Level of Protection
Definition of cleanroom class (parameters, building materials, room requirements, HVAC systems)
Requirements for personnel and material in the different classes (clothing, training, type of materials, etc.)
Requirements on entry conditions for personnel and material ( change procedures )
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Module 3, Part 1: Introduction and overview Slide 17 of 20 WHO - EDM
Air Handling Systems
Parameters influencing Levels of Protection (1)
Annex 1, 17.4
Air Handling System
Production RoomWith
DefinedRequirements
SupplyAir
OutletAir
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Module 3, Part 1: Introduction and overview Slide 18 of 20 WHO - EDM
Air Handling Systems
Parameters influencing Levels of Protection (2)1 Number of particles in the air
2 Number of micro-organisms in the air or on surfaces
3 Number of air changes for each room
4 Air velocity
5 Air flow pattern
6 Filters ( type, position )
7 Air pressure differentials between rooms
8 Temperature, humidity
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Module 3, Part 1: Introduction and overview Slide 19 of 20 WHO - EDM
Air Handling Systems
Cleanroom Classdefined by
Critical Parameters
Air HandlingSystem
Additional Measures
Parameters influencing Levels of Protection (3)
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Air Handling Systems
Parameters influencing Levels of Protection (4)
Air handling systems:
Are the main tool for reaching required parameters
But are not sufficient as such
Need for additional measures such as
appropriate gowning (type of clothing, proper changing rooms) validated sanitation adequate transfer procedures for materials and personnel
Annex 1, 17.10 to 17.16