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API Manufacturing: SOP for Stability Testing of API Batches – V 2.0

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API Manufacturing: SOP for Stability Testing of API Batches – V 2.0

Standard Operating Procedure for Stability Testing of API Batches

Department API Manufacturing
SOP No. SOP/API/130/2025
Supersedes SOP/API/130/2022
Page No. Page 1 of 9
Issue Date 13/04/2025
Effective Date 15/04/2025
Review Date 13/04/2026

1. Purpose

To define the procedure for conducting stability testing of Active Pharmaceutical Ingredient (API) batches to assess product integrity over time and establish or confirm shelf-life in accordance with ICH Q1 guidelines.

2. Scope

This SOP applies to all Quality Control and Quality Assurance personnel involved in the planning, execution, evaluation, and documentation of stability studies for development, validation, and commercial batches of APIs.

3. Responsibilities

  • QC Analyst: Perform stability sample testing as per defined intervals and STP.
  • QA Officer: Monitor storage conditions and maintain stability chambers.
  • Stability Coordinator: Maintain inventory, pull schedules, and data compilation.
  • QC Reviewer: Verify results and compile interim and final stability reports.
See also  API Manufacturing: SOP for Prevention of Cross Contamination during Drying - V 2.0

4. Accountability

The Head – Quality is accountable for the scientific justification, regulatory compliance, and execution of the stability program for API batches.

5. Procedure

5.1 Study Design

  1. Refer to ICH Q1A(R2) and ICH Q1E for designing stability protocols.
  2. Include:
    • Study type (accelerated, long-term, intermediate)
    • Storage conditions (25°C/60% RH, 30°C/65% RH, 40°C/75% RH)
    • Testing intervals (e.g., 0, 3, 6, 9, 12, 18, 24 months)
    • Specifications to be monitored (appearance, assay, impurities, moisture content, etc.)

5.2 Sample Storage

  1. Stability samples must be:
    • Representative of production batches
    • Packed in containers that simulate market packaging
    • Labeled with unique stability ID, batch number, storage condition, and interval schedule
  2. Place samples in qualified stability chambers monitored continuously using calibrated temperature and humidity sensors.

5.3 Testing Procedure

  1. At each interval, withdraw samples per schedule and perform testing as per STP.
  2. Ensure all tests are conducted within ±5 days of the scheduled interval date.
  3. Use validated analytical methods and retain all chromatograms and raw data for review.
  4. Document observations such as color change, precipitation, or odor.
See also  API Manufacturing: SOP for Use of Cooling Towers and Condensers in Recovery - V 2.0

5.4 Data Compilation and Evaluation

  1. Compare results against acceptance criteria and note any trends.
  2. Prepare interim reports after each interval and a comprehensive report at the end of the study.
  3. Include graphical trends for key parameters (e.g., assay, impurity).

5.5 Out-of-Trend or OOS Results

  1. If any OOT or OOS result is observed:
    • Notify QA immediately
    • Initiate deviation/investigation
    • Conduct root cause analysis
    • Evaluate impact on shelf-life and future batches

5.6 Record Keeping and Archival

  1. All stability data, test records, and reports must be retained for at least 5 years post expiry of the batch.
  2. Ensure electronic and physical copies are secured and backed up.

6. Abbreviations

  • API: Active Pharmaceutical Ingredient
  • STP: Standard Test Procedure
  • OOS: Out of Specification
  • OOT: Out of Trend
  • ICH: International Council for Harmonisation
  • RH: Relative Humidity

7. Documents

  1. Stability Protocol
  2. Stability Sample Inventory Log (Annexure-1)
  3. Stability Pull and Testing Log (Annexure-2)
  4. Stability Reports
See also  API Manufacturing: SOP for In-Process Sampling Technique - V 2.0

8. References

  • ICH Q1A(R2) – Stability Testing of New Drug Substances and Products
  • ICH Q1E – Evaluation of Stability Data
  • 21 CFR Part 211 – US FDA cGMP
  • WHO Technical Report Series 1010

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Stability Sample Inventory Log

Date Stability ID Batch No. Condition Container Qty Initial Weight
13/04/2025 STB-API-001 API-20250413 25°C/60% RH 10 500 g

Annexure-2: Stability Pull and Testing Log

Date Stability ID Interval Tests Performed Analyst Reviewed By
13/07/2025 STB-API-001 3 Months Assay, Impurity Sunita Reddy Rajesh Kumar

Revision History:

Revision Date Revision No. Details Reason Approved By
01/01/2022 1.0 Initial Release Regulatory Requirement QA Head
13/04/2025 2.0 Inclusion of pull log and OOT section Audit Observation QA Head
API Manufacturing V 2.0 Tags:API batch record, API BMR, API calibration, API centrifuge, API cleaning, API crystallization, API deviation, API documentation, API drying, API equipment cleaning, API filtration, API GMP compliance, API granulation, API hold time, API impurities, API line clearance, API manufacturing, API process, API quality control, API reactor, API sampling, API solvent handling, API validation, API waste disposal, API yield

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Standard Operating Procedures V 1.0

  • Aerosols
  • Analytical Method Development
  • Bioequivalence Bioavailability Study
  • Capsule Formulation
  • Clinical Studies
  • Creams
  • Data Integrity
  • Dental Dosage Forms
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NEW! Revised SOPs – V 2.0

  • Aerosols V 2.0
  • Analytical Method Development V 2.0
  • API Manufacturing V 2.0
  • BA-BE Studies V 2.0
  • Biosimilars V 2.0
  • Capsules V 2.0
  • Creams V 2.0
  • Elixers V 2.0
  • Ointments V 2.0
  • Raw Material Warehouse V 2.0
  • Tablet Manufacturing V2.0

New Publication: A must for All.

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