Operational Qualification Protocol for the Capsule Filling Machine Protocol No. EQ- National Institute of Health Operational Qualification Protocol Equipment: Capsule Filling Machine Protocol #: Date: 16 March, 2010 Facility: National Institute of Health Location: Building 10 Room 1N249 Bethesda, MD 20892 Revision: Original Title: Operational Qualification Protocol for the Capsule Filling Machine. Objective: The objective of this protocol is to document the satisfactory operation of the Capsule Filling Machine used for manufacturing at National Institute of Health Written By: Michael Molloy Title: Consultant Signature: Date: Approved By: ______________________ Title: _____________________________ Signature: Date: Approved By: ______________________ Title: _____________________________ Approved By: ______________________ Title: _____________________________
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Operational Qualification Protocolfor the Capsule Filling Machine
Protocol No. EQ-
National Institute of HealthOperational Qualification Protocol
Equipment:Capsule Filling Machine
Protocol #: Date:16 March, 2010
Facility:National Institute of Health
Location:Building 10 Room 1N249Bethesda, MD 20892
Revision:Original
Title:Operational Qualification Protocol for the Capsule Filling Machine.Objective:The objective of this protocol is to document the satisfactory operation of the Capsule Filling Machine used for manufacturing at National Institute of Health
PROPRIETARY INFORMATION:Unauthorized Duplication Is Prohibited
DOCUMENT NUMBER DATE: 3/16/10 PAGE: 1 of 36
REVISION NUMBER 1
Author: Michael Molloy ______________________ Revision DATE: N/A
Operational Qualification
EQUIPMENT NAME: Capsule Filling Machine
OPERATIONAL QUALIFICATION
FOR THE
Capsule Filling Machine
INSTALLED
AT
NATIONAL INSTITUTE OF HEALTH
BUILDING 10 ROOM 1N249BETHESDA, MD 20892
QUALIFICATION PROCESS SOLUTIONS
13406 BLYTHENIA RD
PHOENIX, MD 21131
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TABLE OF CONTENTS
1.0 Purpose32.0 Scope 33.0 Equipment Description 34.0 Responsibilities 45.0 Reference Documents 46.0 Definitions 57.0 Test Function Number One: OQ Signature Verification List (Attachment #1) 58.0 Test Function Number Two: Test Equipment (Attachment #2) 59.0 Test Function Number Three: Procedure List (Attachment #3) 610.0 Test Function Number Four: Training Verification (Attachment #4) 611.0 Test Function Number Five: Operator Controls and Indicators (Attachment #5) 612.0 Test Function Number Six: Functional Verification (Attachment #6) 713.0 Test Function Number Seven: Alarms, Safeties and Interlocks (Attachment #7) 714.0 Test Function Number Eight: Sequence of Operations (Attachment #8) 715.0 Test Function Number Nine: Maximum / Minimum Values (Attachment #9) 716.0 Deviation Reporting Log (Attachment #10) 817.0 Operational Qualification Protocol Review (Attachment #11) 818.0 Summary Report Requirements 819.0 Attachment List10
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1.0 Purpose
The objective of this protocol is to verify that the Capsule Filling Machine, described in Section 3.0, operates in accordance to manufacturers’ specification, and in accordance with Current Good Manufacturing Practices (cGMP’s).
2.0 Scope
This Operational Qualification pertains to the verification of the operation of the equipment described in Section 3.0 of this protocol installed in the National Institute of Health, Building 10 room 1N249, Bethesda MD, 20892. This protocol is specific to the Capsule Filling Machine and related instrumentation and equipment. This protocol is specific to the Capsule Filling System, and related instrumentation and equipment, and does not address other facility, or facility related equipment and systems.
3.0 Equipment Description
The Capsule Filling Machine (Model : Zanasi 6F serial 35XXX) is a hard gelatine capsule filler, which is designed for filling liquids, powders, granular product, pellets and tablets. The filler is designed to accommodate capsules size 0,1,2,3 and 4. The output of the filler is adjustable with a maximum production rate of 6000-6120 capsules/hr dependant upon process selection.
The filler is an alternate movement capsule filling machine provided with a rotary stage that provides clockwise axis centered slip stick motion to transport capsules thru 8 process stages. The stages are:
1) Capsule feed (w/relative automatic selection via optional unit)2) Capsule orientation , positioning and opening (equipped w/ 8 stages)3) Capsule separation pre-filling4) Capsule product filling5) Unopened capsule selection (Automatic)6) Capsule alignment and closure7) Capsule ejection8) Capsule selection (automatic empty and partial fill segregation)
The capsule filling machine is comprised of the following major elements:
1) Base2) Motorization3) Moving Parts4) Protective hood5) Electric cabinet and control panel6) Size-change parts for process changeover7) Manual controls8) Powder feed unit9) Powder layer and leveling control10) Pellet or tablet dosing unit11) Powder or pellet dosing unit12) Defective capsule selection unit13) Capsule closing unit
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14) Capsule selection unit15) Liquid dosing unit16) Central stage17) Emergency stop push button18) Electric extension plug
The following general parameters apply to the Zanasi 6F
1) Dimension: 2000mm W x 1670 mm H x 2140 mm L2) Weight 1050 kg3) Power 480 V – 1.5 kw4) Air
4.0 Responsibilities
4.1 Qualification Process Solutions, LLC.4.1.1 It is the responsibility of QPS to write this protocol.4.1.2 It is the responsibility of QPS to execute this protocol.
4.2 National Institutes of Health (SI)4.2.1 Following the execution, NIH will approve the final report associated with this
protocol, indicating the executed protocol was completed correctly and all acceptance criteria were met.
5.0 Reference Documents
5.1 Drawing: 400024-00 Capsule Filling Machine Assembly 5.2 Drawing: 4400d010-37 Base Machine5.3 Drawing: 4401d011-28 Kinematic Motion Unit5.4 Drawing: 4402d012-11 Powder Unit5.5 Drawing: 4403d013-15 Manual Return Unit5.6 Drawing: 4404d014-05 Plate Unit5.7 Drawing: 4405d015-11 Capsule Feeding and Opening Unit5.8 Drawing: 4407d017-01 Powder Feeding Unit5.9 Drawing: 4408d018-07 Compression/Powder Ejection Unit5.10 Drawing: 4409d019-11 Reject Sorting Unit and Closing Counterplate5.11 Drawing: 4410d020-11 Capsule Ejection Unit5.12 Drawing: 4411d021-11 Cleaning Unit5.13 Drawing: 4005d002-03 Components Added to Basic Machine5.14 Drawing: 4002d004-07 Components Added to Basic Machine 5.15 Drawing: 4004d004-05 Components Added to Basic Machine5.16 Drawing: 4008d004-05 Components Added to Basic Machine5.17 Drawing: 4009d004-11 Components Added to Basic Machine5.18 Drawing: 4402d028-03 Components Added to Rotary Tank5.19 Drawing: 4410d090-12 Capsule Chute without SPC5.20 Drawing: 4005d141-06 Powder/Pellet Capsule Equipment Unit F15.21 Drawing: 4005d142-06 Powder/Pellet Capsule Equipment Unit F25.22 Drawing: 4005d143-06 Powder/Pellet Capsule Equipment Unit F3
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including:MaintenanceSafety NoticesCE Conformity DocumentsTest Reports and Equipment Certs
6.0 Definitions
6.1 Critical Instrumentation – Critical instruments are defined as those whose performance will affect the operation of the system and/or the quality attributes of the processed materials. Critical instruments are calibrated and certified using standards that are traceable to NIST (National Institutes of Standards and Testing).
6.2 Non-Critical Instrumentation – Instrumentation provided for indication or convenience purposes only.
7.0 Test Function Number One: OQ Signature Verification List (Attachment #1)
7.1 ObjectiveTo identify and document all personnel involved in executing this protocol.
7.2 Procedure Verify that each person who executes this protocol signs Attachment #1. Each person must be identified by name, title, company, signature, initials and date on the attached form.
7.3 Acceptance CriteriaSignatures from all personnel involved in execution of this protocol shall be present.
8.0 Test Function Number Two: Test Equipment (Attachment #2)
8.1 Objective To verify and document all test equipment
8.2 Procedure 8.2.1 Complete a list of all the instruments required for conducting OQ testing.
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8.2.2 Verify that the test equipment/instruments are calibrated and the reference standards are traceable to National Institute for Standards and Technology (NIST) or other approved standard.
8.2.3 Complete the applicable attachment, indicating the equipment description, ID/serial number, calibration date, re-calibration date
8.3 Acceptance CriteriaAll equipment required for execution shall be calibrated with copies of calibration records attached.
9.0 Test Function Number Three: Procedure List (Attachment #3)
9.1 ObjectiveTo verify the operating Standard Operating Procedures (SOP’s) provide adequate direction and control over the operation of the equipment.
9.2 Procedure9.2.1 Verify that the operational SOP provides personnel adequate direction and control
over the operation of the equipment. (The SOP’s used for execution may be in draft form.)
9.2.2 Complete the applicable attachment with a list of all applicable SOP’s. 9.2.3 Redline the SOP’s with an operator and validation personnel. Attach the redline copy
to this qualification protocol. 9.3 Acceptance Criteria
All associated SOP’s for operation and execution shall be reviewed and documented.
10.0 Test Function Number Four: Training Verification (Attachment #4)
10.1 ObjectiveTo document applicable personnel have received the required training for operation of the equipment.
10.2 Procedure10.2.1 Document all personnel executing this protocol that have been trained on the
approved/draft SOP for the equipment.10.2.2 List all SOP’s used during the execution of this protocol10.2.3 Complete required training forms in accordance with NIH’s training requirements.
10.3 Acceptance CriteriaTraining shall be performed on all SOP’s used during the execution of this qualification protocol.
11.0 Test Function Number Five: Operator Controls and Indicators (Attachment #5)
11.1 Objective To verify the controls and indicators operate as specified by manufacturer recommendations.
11.2 Procedure11.2.1 Manually operate the control switches listed in the applicable attachment.11.2.2 Visually verify and document the actual responses.11.2.3 Document any discrepancies in Attachment #10, Deviation Reporting Log. If any
variances/deviations are present, complete the appropriate deviation/variance form.11.3 Acceptance Criteria
All operator controls and indicators tested shall conform to the expected response.
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12.0 Test Function Number Six: Functional Verification (Attachment #6)
12.1 Objective To verify and document the operation and functionality of the equipment.
12.2 Procedure12.2.1 Follow the procedures in the applicable attachments. 12.2.2 Visually verify and document the actual responses as pass or fail against the expected
results.12.2.3 Document all operational parameters used during execution. 12.2.4 Document any discrepancies in Attachment #10, Deviation Reporting Log. If any
variances/deviations are present, complete the appropriate deviation/variance form.12.3 Acceptance Criteria
All functional requirements must conform to the expected responses.
13.0 Test Function Number Seven: Alarms, Safeties and Interlocks (Attachment #7)
13.1 Objective To verify and document the operation and functionality of the alarms, safeties and interlocks.
13.2 Procedure13.2.1 Follow the procedures in the applicable attachments. 13.2.2 Visually verify and document the actual responses as pass or fail against the expected
results.13.2.3 Document all operational parameters used during execution. 13.2.4 Document any discrepancies in Attachment #10, Deviation Reporting Log. If any
variances/deviations are present, complete the appropriate deviation/variance form.13.3 Acceptance Criteria
All safeties and interlock requirements must conform to the expected responses.
14.0 Test Function Number Eight: Sequence of Operations (Attachment #8)
14.1 ObjectiveTo verify and document the operational sequence of the system.
14.2 Procedure14.2.1 Execute the procedures in the order listed.14.2.2 Observe the expected operations and write “Pass” if the results were as expected, and
“Fail” if the expected operation did not take place. 14.2.3 Document any discrepancies in Attachment #10, Deviation Reporting Log. If any
variances/deviations are present, complete the appropriate deviation/variance form.14.3 Acceptance Criteria
The operating sequence occurs as expected.
15.0 Test Function Number Nine: Maximum / Minimum Values (Attachment #9)
15.1 ObjectiveTo verify the maximum and minimum allowable values of changeable setpoints.
15.2 Procedure 15.2.1 Display the changeable setpoint on the applicable attachment and test maximum and
minimum values.
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15.2.2 Visually verify and document the actual results of the functions that appear on the operator interface.
15.2.3 Document any discrepancies in Attachment #10, Deviation Reporting Log. If any variances/deviations are present, complete the appropriate deviation/variance form.
15.3 Acceptance CriteriaThe actual results of the changeable setpoint limits shall conform to the expected responses.
16.0 Deviation Reporting Log (Attachment #10)
16.1 Objective: To document any deviation to the stated test procedure or acceptance criteria, and to evaluate the deviation relative to acceptability of the qualification study.
16.2 Procedure: 16.2.1 Document all deviations found during execution using the Deviation Report Form that
is with the Deviation Reporting Log. Make copies of the form for each logged Deviation.
16.2.2 Deviations caused by Out of Specification (OOS) Conditions. If during the evaluation of equipment parameters against specifications, the equipment fails to meet predetermined acceptance criteria, a formal deviation report investigates the cause. In these cases, the cause must be known prior to continuing the protocol execution since a true failure in equipment performance is likely to affect the completion of the protocol. The protocol deviation report determines 1) if the acceptance criteria are correct and current with user requirements and manufacturer's ratings, or 2) if there is an immediate and obvious explanation for the failure. If a true failure is documented, then appropriate root cause analysis and corrective actions ensue and are agreed to between the protocol executors and the department owners and QA. The protocol deviation report documents the conclusion to this investigation and any appropriate retesting and an impact assessment on the portions of the protocol executed prior to the documented failure.
16.2.3 Completed Deviation Report Forms are submitted to QA for signature acceptance.
17.1 Objective To document that this protocol has been reviewed for completeness as per Qualification Process Solutions, LLC Requirements.
17.2 ProcedureComplete attachment with name, title, signature and date.
18.0 Summary Report Requirements
18.1 Objective To provide an overview of the test results during the execution of this operational qualification.
18.2 Procedure18.2.1 Generate a final summary on completion of this protocol execution.
18.2.1.1 Compile a summary of the results obtained.18.2.1.2 Generate a conclusion, based on these results, of the acceptability of the
qualification results.
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18.2.1.3 Include a statement of conformance to the specified acceptance criteria, evaluated in conjunction with the approved deviations and corrective actions taken.
18.2.1.4 Determination of acceptability of the protocol, as executed.18.2.2 Attach the completed, executed and approved protocol to the final report.18.2.3 Attached copies of all completed, approved Deviation Report and Corrective Action
Forms, where necessary.
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19.0 Attachment List
Attachment #1 OQ Signature Verification List 11
Attachment #2 Test Equipment 12Attachment #3 Procedure List 13Attachment #4 Training Verification 14Attachment #5 Operator Controls and Indicators 15Attachment #6 Functional Verification 19Attachment #7 Alarms, Safeties and Interlocks 25Attachment #8 Sequence of Operation 31Attachment #9 Maximum / Minimum Values 33Attachment #10 Deviation Reporting Log 34Attachment #11 Operational Qualification Protocol Review 36
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Attachment #1 OQ Signature Verification List
This section identifies the personnel conducting the Operational Qualification. Each person who will be executing this protocol shall complete an entry on the page.
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Attachment #2 Test Equipment
This attachment identifies the instruments, equipment, and materials that are not part of the equipment or system being qualified, but are used in this qualification.
Acceptance Criteria: A list of written procedures that are used to operate the equipment is provided above. If procedures are in draft form, attach a copy to the executed protocol.
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Attachment #6 Functional Verification
Verify that the equipment/system operations function as indicated.
Input Address
Input Test Description Expected ResultsPass/Fail
Performed By/Date
I 00.00 Machine Start Push Button Energized(SB 5.17)
Lamp HL5.6 Green Machine starts
Machine Start Push Button Not Energized (SB 5.17)
Lamp HL5.6 off Machine stops
I 00.01Handwheel Detector Sensor Energized(BI 8.3)
LED E REDMachine won’t start
Handwheel DetectorSensor not Energized (BI 8.3)
LED E offMachine will start
I 00.02 Jog Button energized (XC5.15) Machine starts, after 20 sec LED Z Red
Jog Button de-energized (XC5.15) Machine stops
I 00.03Machine Start Relay Energized (KA8.6) LED B Green
Machine Start Relay De-energized (KA8.6) LED B off
I 00.04Guard MicroSwitchSwitch Energized (A 4A.9)
LED G offMachine will start
Guard MicroSwitchSwitch De-energized(A 4A.9)
LED G REDMachine wont start
I 00.05Mixer Auto/ManualSwitch energized (SA7.2) LED T Green
Mixer Auto/ManualSwitch de-energized (SA7.2) LED T off
I 00.06Emergency Push Button Button energized (SE 4A.4)
ESTOP Button RED, Machine stopped
Emergency Push ButtonButton de-energized (SE 4A.4) ESTOP Button off
Test Expected Result Pass/Fail Initial/DatePower Up the Equipment. Manually actuate the I/O by either simulating a condition or forcing a condition to activate the output. Verify the system I/O act accordingly.
I/O operates as expected
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Attachment #6 Functional Verification
Verify that the equipment/system operations function as indicated.
Input Address
Input Test Description Expected Results Pass/Fail
Performed By/Date
I 00.07Powder Min. Level Detector 2Sensor energized (BC8.10) LED L Red
Powder Min. Level Detector 2Sensor de-energized (BC8.10) LED L off
I 00.08Locked Inverter Signal energized (AR1.14)
LED D flashing RED
Locked Inverter Signal de-energized (AR1.14) LED D off
I 00.09Powder Charging AutoSwitch energized (SA7.14) LED V Green
Powder Charging Auto Switch de-energized (SA7.14) LED V off
I 00.10Powder Charging Manual Switch energized (SA7.14) LED X Green
Powder Charging Manual Switch de-energized (SA7.14) LED X off
I 00.11Powder Min. Level Detector 4Sensor energized (BC8.14) LED L Red
Powder Min. Level Detector 4Sensor de-energized (BC8.14) LED L off
I 01.00Stop PhaseSensor Energized (BI8.15)
LED D flashing RED
Stop Phase Sensor Energized De-energized (BI8.15) LED D off
I 01.01Capsule Minimum LevelSensor Energized (BC8.16)
LED M flashing RED, after 1 min. steady RED
Capsule Minimum Level Sensor Energized Not Energized (BC8.16)
LED M off
I 01.02JOG start Relay energized (KA5.13)
Machine starts while jog is pressed
JOG start Relay de-enegized (KA5.13)
Machine stops when jog is released
I 01.03Guards Control Key Switch energized (SA5.12)
LED G RED
Guards Control Key Switch de-energized (SA5.12)
LED G off
Test Expected Result Pass/Fail Initial/DatePower Up the Equipment. Manually actuate the I/O by either simulating a condition or forcing a condition to activate the output. Verify the system I/O act accordingly.
I/O operates as expected
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Attachment #6 Functional Verification
Verify that the equipment/system operations function as indicated.
Input Address
Input Test Description Expected Results Pass/Fail
Performed By/Date
I 01.04 Program Stop On (SB5.17D1)Program initiated machine stop
Program Stop Off (SB5.17D1)Machine enabled normal
I 01.05Machine motor brake control Relay energized (AR1.14)
Machine brake engaged
Machine motor brake control Relay de-energized (AR1.14)
Machine brake dis-engaged
I 01.06 Mixer On/Off Switch energized (KT10.15)
LED T Green
Mixer On/Off Switch de-energized (KT10.15)
LED T off
I 01.07 Pellet Group 1 Selector Switch On (SA9.5)
Pellet Group 1 enabled.
Pellet Group 1Selector Switch Off (SA9.5)
Pellet Group 1 dis-abled.
I 01.08 Pellet Group 2 Selector Switch On (SA9.6)
Pellet Group 2 enabled.
Pellet Group 2 Selector Switch Off (SA9.6)
Pellet Group 2 dis-abled.
I 01.09 Pellet Group Sensor On (SA9.6)LED N Red no pellets
Pellet Group Sensor Off (SA9.6) LED N off
I 01.10Motor Overload Cutout energized (QM7.11)
LED D Red Machine stops
Motor Overload Cutout de-energized (QM7.11)
LED D off
I 01.11Air PressureSensor energized (SP9.9)
LED F off
Air Pressure Sensor de-energized (SP9.9)
LED F Red
Test Expected Result Pass/Fail Initial/DatePower Up the Equipment. Manually actuate the I/O by either simulating a condition or forcing a condition to activate the output. Verify the system I/O act accordingly.
I/O operates as expected
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Attachment #6 Functional Verification
Verify that the equipment/system operations function as indicated.
Output Address
Output Test Description Expected ResultsPass/Fail
Performed By/Date
O10.00 Mixer Start (KA10.11)Mixer starts when bit is enabled.
O10.01 Machine Stop (KA10.12)Machine stops when bit is enabled.
O10.02 Remote Machine Start (KA10.13)Machine starts when bit is enabled.
O10.04 Mixer ON/OFF (KT10.15)
Mixer is on when bit is enabled. Mixer is off when bit is not enabled.
Test Expected Result Pass/Fail Initial/DatePower Up the Equipment. Manually actuate the I/O by either simulating a condition or forcing a condition to activate the output. Verify the system I/O act accordingly.
I/O operates as expected
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Attachment #6 Functional Verification
Verify that the equipment/system operations function as indicated.
Procedure Expected Result Pass/Fail Initials/Date
Machine Start/Stop Sequence
1. With no dosing unit installed start pumps/aspirator. Press machine start pushbutton on control panel.2. While running push machine stop pushbutton.3. With unit running verify proper operation of the emergency stops provided on the machine and the control panel.
1. Machine starts and LED R illuminates green.
2. Machine stops
3. Machine stops immediately
Pass/Fail
Capsule Feed System
1. Manually fill hopper with capsules. No dosing units installed. Start pumps/aspirator. Initiate machine start.2. Verify capsule minimum level operates correctly by positioning sensor to simulate no capsules.3. Verify operation of the Sort/Unopened capsule system. Manually insert 4 unopened capsules in the feed channels. Operate the machine4. Adjust machine speed to 6000 Caps/hr
1. Capsules flow into the machine is initiated until stop pushbutton is pressed.
2. LED M is lit.
3. Closed capsules will be ejected into the unopened capsule container.
4. Verify machine is at minimum feed of 6000 caps/hr
Pass/Fail
Powder Feed System
1. Load upper powder hopper ¾ full. Turn the manual feed selector on the control panel.2. With tube full of powder calibrate capacitive sensor per IMA 35064M04 (Instruction manual)3. Utilize “Jog” to start and stop machine until product bowl is filled..4. Place feed selector in “auto” and observe powder coming out of dosators and a “tablet falls into capsule bottom. Adjust dosators in accordance with IMA 35064M04 (Instruction manual). 5. Adjust powder layer in accordance with IMA 35064M04 (Instruction manual).
1. Observe powder flow into lower powder hopper via plexiglass fill tube
2. Observe indicator light on capacitive sensor turns on.
3. Observe product bowl.
4. Confirm proper compactness and verify dosator piston projects .5mm from dosating unit.
5. Observe powder layer for proper height and homogeneity.
Pass/Fail
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Pellet System
1. Install pellet unit 2 in the powder dosing unit station in accordance with IMA 35064M04 (Instruction manual). With the main switch on, use key lock and open the door guard and place selector switch C to on.2. After filling the hopper with product adjust the sensitivity of the pellet level sensors in accordance with IMA 35064M04 (Instruction manual).
1. Observe pellets filling dosators.
2. Observe no pellets LED N is Red when pellets are below this sensor.
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Attachment #8 Sequence of Operation
Setup equipment to run with the appropriate operational parameters for a typical Production Cycle. Run equipment. Inspect cycle run data and verify it meets acceptance criteria.
Verify the sequence of operation of the pre-programmed cycle in Attachment #9.
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Attachment #8 Sequence of Operation
Setup equipment to run with the appropriate operational parameters for a typical Production Cycle. Run equipment. Inspect cycle run data and verify it meets acceptance criteria.
Verify the sequence of operation of the pre-programmed cycle in Attachment #9.
Qualification Process Solutions, LLC signature below verifies this Operational Qualification protocol has been reviewed, for completeness and for accuracy of calculations. A separate final report will be written and attached to this protocol. The final report will discuss any deviations, conclusions, and/or recommendations resulting from the execution of the protocol.
Name (print):_____________________________________
Company (print): __________________________________