Standard Operating Procedure for Start-Up and Shutdown of Manufacturing Equipment

Department	Creams
SOP No.	SOP/CRM/090/2025
Supersedes	SOP/CRM/090/2022
Page No.	Page 1 of 6
Issue Date	21/01/2026
Effective Date	26/01/2026
Review Date	21/01/2027

1. Purpose

The purpose of this SOP is to outline the procedure for the start-up and shutdown of manufacturing equipment in the Creams Department. The objective is to ensure that equipment is safely started and shut down, maintaining product quality and preventing equipment damage.

2. Scope

This SOP applies to all manufacturing equipment used in the Creams Department, including mixers, homogenizers, filling machines, and other production-related machinery. It covers the steps for starting up and shutting down equipment before and after production runs.

3. Responsibilities

• Production Team: Responsible for following the start-up and shutdown procedures to ensure equipment operates safely and efficiently.
• Maintenance Team: Ensures that equipment is regularly maintained and in good working condition for both start-up and shutdown processes.
• Quality Control (QC): Verifies that equipment is properly cleaned and calibrated before use, ensuring compliance with product quality standards.

4. Accountability

The Head of Production is accountable for ensuring that the start-up and shutdown procedures are followed. The QA Manager is responsible for ensuring that all necessary checks are completed before starting the equipment and that the equipment is safely shut down after production.

5. Procedure

5.1 Pre-Start-Up Checks

1. Ensure that the equipment has been cleaned according to the cleaning SOP and is free from any product residues or contaminants.
2. Verify that all components of the equipment, including motors, pumps, valves, and hoses, are correctly installed and secure.
3. Check that all safety guards, covers, and emergency stop buttons are in place and functional.
4. Ensure that all necessary raw materials, such as cream bases and active ingredients, are available and properly prepared for use.
5. Check that all necessary utilities, such as power, water, and air supply, are connected and functioning properly.
6. Ensure that the equipment’s control system, including software or manual settings, is configured to the required parameters for the production run.

5.2 Start-Up Procedure

1. Turn on the main power supply to the equipment and verify that all control systems are functioning properly.
2. Gradually start the equipment according to the manufacturer’s guidelines. Monitor the system for any abnormal noises or vibrations during startup.
3. Verify that all moving parts, such as mixers or pumps, are operating smoothly and within specified speeds or pressures.
4. Monitor the temperature and other critical parameters to ensure they fall within acceptable ranges.
5. If the equipment includes automated settings, ensure that all parameters, such as batch size, time, and speed, are correctly inputted before operation.
6. Perform a dry run or test run without materials (if applicable) to ensure that all equipment components are functioning as expected.
7. Once the equipment is fully operational, initiate production and monitor the equipment regularly during the process to detect any issues early on.

5.3 Monitoring During Operation

1. Regularly monitor equipment during the production process for any signs of malfunction or deviation from normal operation.
2. Ensure that any abnormal readings, such as temperature fluctuations or pressure drops, are addressed immediately by stopping the equipment and troubleshooting the cause.
3. Record any issues or adjustments made during the operation in the Production Log (Annexure-1) to maintain a record of the equipment’s performance.

5.4 Pre-Shutdown Checks

1. Ensure that the production process has been completed, and all materials have been processed as required.
2. Check that the equipment is free from any remaining raw materials or cream residue. Perform a cleaning cycle if necessary before shutdown.
3. Ensure that the equipment has been properly emptied and cleaned, and that all valves and hoppers are closed securely.
4. Confirm that all safety measures are in place and that the equipment can be safely shut down without risk of contamination or equipment damage.

5.5 Shutdown Procedure

1. Turn off the equipment following the manufacturer’s shutdown procedure, ensuring that the equipment is powered down safely and securely.
2. Switch off any auxiliary systems, such as water, air, or electrical supplies, that are no longer required.
3. Perform any post-operation checks or maintenance as required, such as draining the system, cleaning, or lubricating moving parts.
4. Ensure that all safety features, including emergency stop buttons, are activated, and the system is in a standby state.
5. Record the shutdown time and any maintenance or cleaning performed in the Equipment Maintenance Log (Annexure-2).

5.6 Post-Shutdown Maintenance

1. Inspect all equipment parts for wear and tear. Check for any signs of malfunction, and replace parts if necessary before the next operation.
2. Document any issues found during the shutdown and record corrective actions taken in the Equipment Maintenance Log (Annexure-2).
3. Schedule any necessary maintenance for equipment that has shown signs of wear or damage during the shutdown process.

5.7 Documentation

1. Record all relevant details of the start-up and shutdown process in the Production Log (Annexure-1), including the time taken for startup, any issues encountered, and any adjustments made during operation.
2. Document any maintenance or repairs performed during the start-up or shutdown process in the Equipment Maintenance Log (Annexure-2).

5.8 Final Approval

1. The QA team must review the start-up and shutdown documentation, including the maintenance records, to ensure compliance with the SOP and GMP standards before the equipment is used for the next batch.
2. If any deviations are noted, the batch should be reviewed and corrective actions should be taken before proceeding to the next production phase.

6. Abbreviations

• GMP: Good Manufacturing Practices
• QC: Quality Control
• QA: Quality Assurance
• PPE: Personal Protective Equipment

7. Documents

1. Annexure-1: Production Log
2. Annexure-2: Equipment Maintenance Log

8. References

• Good Manufacturing Practices (GMP) Guidelines – 21 CFR Part 211
• International Conference on Harmonisation (ICH) Q7 – Good Manufacturing Practice for Active Pharmaceutical Ingredients
• FDA Guidelines for Equipment Operation and Maintenance

9. SOP Version

Version: 2.0

10. Approval Section

	Prepared By	Checked By	Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Production Log

Batch Number	Start-Up Time	Shutdown Time	Operator	Comments
12345	08:00 AM	05:00 PM	Jane Smith	Successfully completed operation

Annexure-2: Equipment Maintenance Log

Equipment ID	Maintenance Date	Maintenance Type	Operator	Comments
EM-001	21/01/2026	Inspection and lubrication	John Doe	Successfully completed

Revision History:

Revision Date	Revision No.	Revision Details	Reason for Revision	Approved By
01/03/2024	1.0	Initial Version	New SOP Creation	QA Head
01/03/2025	2.0	Format Revision and Updates	Standardization of Document	QA Head