There are various contamination sources in an aseptic area, which are discussed below:
Personnel : Those supervising, performing, or controlling drug manufacturing are a potential source of microbial contamination, due to the following reasons:
- Inadequate training,
- Direct contact between the hands and starting materials, primary packing materials, and intermediate or bulk products,
- Improper hygiene,
- Unauthorised personnel entering the production, storage, and product control areas,
- Insufficient gowning and protective equipment, and
- Eating, drinking, or smoking within the storage and processing areas.
Buildings and Facilities : These are also important contributors to microbial contamination due to the following reasons:
- Inadequate size and organisation of the space, which lead to selection errors (such as mix-ups or cross-contamination between consumables, raw materials, in-process materials, and finished products),
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Poor filth and pest controls,
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Rough floors, walls, and ceilings,
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Absence of air filtration systems,
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Inadequate lighting and ventilation systems,
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Poorly located vents, ledges, and drains, and
- Improper washing, cleaning, toilet, locker facilities, sanitary operation, and personal cleanliness.
Equipment and Utensils : These are used during processing, holding, transferring, and packaging. They are the common sources of microbial contamination due to the following reasons:
- Unsuitable design, size, corrosion-causing materials, static material accumulation, and/or adulteration with lubricants, coolants, dirt, and sanitising agents,
- Inadequate cleaning and sanitisation,
- Inefficient cleaning and maintenance due to their designing,
- Inappropriate calibration and irregular service, and
- Using defective equipment.
Raw Materials : These are used during production and are considered a potential source of contamination due to the following reasons:
- Improper storage and handling, which leads to mix-ups or selection errors,
- Microbial or chemical contamination,
- Degradation due to extreme environmental conditions (like heat, cold, sunlight, moisture, etc.),
- Wrong labelling,
- Incorrect sampling and testing, and
- Using materials not meeting the acceptance criteria.
Manufacturing Process : During the manufacturing process, microbial contamination of raw materials, intermediates or packaging materials can widely occur due to the following reasons:
- Absence of facilities required for manufacturing of a single product,
- Improper cleaning between batches for minimising the amount of product changeovers,
- Use of an open manufacturing system for exposing the product to the room environment,
- Improper zoning,
- Lacking an area line clearance (as per the approved procedures) after each cleaning process and between each batch, and
- Lack of cleaning status labelling on all equipment and materials used within the manufacturing facility.
HVAC (Heating, Ventilation, and Air Conditioning) System : An inappropriate HVAC system is a possible source of microbial growth and also disperses the contaminants throughout the manufacturing unit. This occurs due to the following reasons:
- Organic materials accumulate in or near HVAC air intakes,
- Inadequate air filtration system,
- Inadequate magnitude of pressure differentials, which causes flow of reversal,
- Incorrect ratio of fresh air to re-circulated air,
- Incapability of accessing ventilation dampers and filtering from outside the manufacturing areas, and
- Non-directional airflow within production or primary packing areas.
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