Standard Operating Procedure for Qualification of Liquid Filling Machines

1) Purpose

The purpose of this Standard Operating Procedure (SOP) is to define the process for qualifying liquid filling machines used in pharmaceutical manufacturing. This SOP ensures that the liquid filling machines are correctly installed, operate according to specifications, and perform consistently under typical production conditions. The qualification process verifies mechanical, electrical, and operational parameters to ensure that the liquid filling process meets the required regulatory and quality standards.

2) Scope

This SOP applies to the qualification of all liquid filling machines used in the pharmaceutical industry for filling liquid formulations into containers such as bottles, vials, and ampoules. It includes the Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) stages. The SOP applies to both new machines and those that have undergone repairs, upgrades, or relocations. The qualification ensures that the liquid filling machine operates effectively, meets fill accuracy standards, and complies with regulatory requirements.

3) Responsibilities

Operators: Responsible for assisting in the IQ, OQ, and PQ processes, ensuring that the liquid filling machine is operated according to the qualification protocols and that critical parameters are monitored and recorded during testing.
Quality Assurance (QA): Ensures that the IQ, OQ, and PQ of the liquid filling machine are carried out in compliance with this SOP and meet all regulatory requirements. QA is responsible for reviewing and approving all qualification reports and documentation.
Production Supervisors: Oversee the qualification processes to ensure that operators follow the protocol and that the machine operates within the specified parameters.
Validation Team: Responsible for developing the qualification protocols, executing the IQ, OQ, and PQ runs, and analyzing the results to ensure the liquid filling machine meets all performance criteria.
Maintenance Personnel: Ensures that the liquid filling machine is properly installed, maintained, and calibrated, and that all mechanical and electrical systems are functioning correctly during the qualification process.

4) Procedure

The following steps should be followed for the IQ, OQ, and PQ of liquid filling machines:

1. Installation Qualification (IQ):
1.1 Review equipment specifications and manufacturer manuals to ensure that the liquid filling machine meets the necessary requirements for installation.
1.2 Verify that all required utilities (e.g., electrical power, compressed air, water supply) are available and meet the specifications required for machine operation.
1.3 Ensure that the installation site meets the required environmental conditions such as temperature, humidity, cleanliness, and space.
1.4 Confirm that all mechanical components are correctly installed, including the filling nozzles, conveyors, and capping or sealing systems.
1.5 Ensure that all electrical components, including sensors, controls, and alarms, are properly connected and functioning.
1.6 Perform a visual inspection to confirm that the equipment is installed according to the manufacturer’s instructions and that all components are intact.
1.7 Complete the IQ documentation, including checklists, equipment manuals, and relevant installation records, ensuring that all information is recorded and signed off by responsible personnel.

2. Operational Qualification (OQ):
2.1 Verify that all operational controls, such as filling volume, filling speed, and nozzle alignment, are properly set and calibrated.
2.2 Conduct an empty run of the liquid filling machine to verify that it operates without issues. Monitor key parameters such as liquid flow rate, filling consistency, and alignment of nozzles.
2.3 Test all control systems, ensuring that the start/stop, filling controls, and emergency stop functions work correctly.
2.4 Inspect the filling process to ensure that containers are filled accurately and consistently with the correct amount of liquid.
2.5 Perform calibration checks to verify that the filling volume is within the specified limits and that any variations are within acceptable tolerances.
2.6 Document the results of the OQ, noting any deviations or issues encountered and corrective actions taken.

3. Performance Qualification (PQ):
3.1 Conduct the filling process using product or simulated product (such as water or an inert solution) and monitor performance under typical production conditions.
3.2 Perform sampling during the filling cycle to measure the volume filled in each container. Ensure that the fill volume falls within the specified range for the product.
3.3 Measure the filling accuracy by calculating the fill variance across multiple containers in a batch, ensuring that the fill volume meets predefined standards.
3.4 Verify that the filling process operates efficiently at the required throughput without compromising accuracy.
3.5 Conduct visual inspections to ensure there are no leaks, overfills, or underfills in the containers.
3.6 Document the results of the PQ, including fill volume data, throughput, and any process deviations. Ensure that all records are signed and reviewed by responsible personnel.

4. Documentation and Reporting:
4.1 Record all data during the IQ, OQ, and PQ processes, including batch records, equipment logs, process parameters, and inspection results for fill accuracy and consistency.
4.2 Ensure that all forms, reports, and certificates are completed and signed by responsible personnel.
4.3 Perform statistical analysis on the collected data to assess the consistency and reliability of the filling process. This analysis should confirm that the machine operates consistently and meets the acceptance criteria for fill accuracy.
4.4 Prepare a final qualification report, summarizing the results of the IQ, OQ, and PQ, including any deviations, corrective actions, and conclusions regarding the liquid filling machine’s performance.

5. Requalification:
5.1 Requalify the liquid filling machine if significant changes are made to the equipment, such as replacing major components, relocating the machine, or modifying the filling system.
5.2 Periodically perform requalification to ensure that the equipment continues to perform as expected and remains in compliance with regulatory requirements.

5) Abbreviations

• IQ: Installation Qualification
• OQ: Operational Qualification
• PQ: Performance Qualification
• QA: Quality Assurance
• SOP: Standard Operating Procedure

6) Documents

• IQ/OQ/PQ Protocol
• Equipment Manufacturer Specifications
• Installation and Setup Reports
• Calibration Records
• Filling Process Records
• Volume Measurement Logs
• Deviation and Corrective Action Reports

7) Reference

• FDA Guidance for Industry: Equipment Qualification
• International Council for Harmonisation (ICH) Q7: Good Manufacturing Practice Guide for Active Pharmaceutical Ingredients
• ISO 9001: Quality Management Systems – Requirements
• USP Chapter 1151: Pharmaceutical Dosage Forms

8) SOP Version

Version 1.0 – Effective Date: DD/MM/YYYY

Annexure

Template 1: IQ/OQ/PQ Test Record

Date	Time	Operator Initials	Test Type (IQ/OQ/PQ)	Test Results	Comments
DD/MM/YYYY	HH:MM	Operator Name	IQ/OQ/PQ	Pass/Fail	Comments

Template 2: Fill Volume Test Log

Batch No.	Test Date	Fill Volume (mL)	Deviation (%)	Pass/Fail	Operator Initials
Batch Number	DD/MM/YYYY	Volume in mL	Deviation Percentage	Pass/Fail	Operator Name

Template 3: Equipment Calibration and Maintenance Log

Equipment Name	Calibration Date	Maintenance Performed	Next Calibration Date	Operator Initials
Liquid Filling Machine Model	DD/MM/YYYY	Maintenance Tasks	DD/MM/YYYY	Operator Name