Gel Manufacturing: SOP for Preservative Efficacy Testing in Gels – V 2.0
Standard Operating Procedure for Preservative Efficacy Testing in Gel Formulations
| Department |
Gel Manufacturing |
| SOP No. |
SOP/GM/065/2025 |
| Supersedes |
SOP/GM/065/2022 |
| Page No. |
Page 1 of 12 |
| Issue Date |
02/06/2025 |
| Effective Date |
04/06/2025 |
| Review Date |
02/06/2026 |
1. Purpose
To define the procedure for performing preservative efficacy testing (PET) on gel formulations to verify the effectiveness of added preservatives against microbial contamination during storage.
2. Scope
This procedure is applicable to all gel formulations that require preservation for long-term stability and microbial protection.
3. Responsibilities
- QC Microbiologist: To execute
and document PET experiments.
QA Officer: To review PET reports and ensure adherence to pharmacopeial standards.
QC Manager: To evaluate data and approve the test results.
4. Accountability
Head – Quality Control shall ensure compliance with this SOP and address any deviations arising during preservative efficacy testing.
5. Procedure
5.1 Sample Selection
- Select a representative batch of gel containing final preservatives in intended concentration.
- Ensure the sample has passed routine microbiological limits before initiating PET.
5.2 Test Organisms
Use the following standardized microbial strains:
- Escherichia coli (ATCC 8739)
- Staphylococcus aureus (ATCC 6538)
- Pseudomonas aeruginosa (ATCC 9027)
- Candida albicans (ATCC 10231)
- Aspergillus brasiliensis (ATCC 16404)
5.3 Inoculum Preparation
- Cultivate strains in appropriate media and harvest cells in sterile saline or buffer.
- Adjust inoculum concentration to achieve ~105 to 106 CFU/mL.
5.4 Inoculation and Incubation
- Inoculate test gels separately with each microbial suspension under aseptic conditions.
- Store inoculated samples at 20°C–25°C protected from light.
5.5 Sampling Schedule
Evaluate microbial viability at Day 0 (immediately after inoculation), Day 7, Day 14, Day 21, and Day 28.
5.6 Enumeration
- Withdraw ~1 g sample at each time point and dilute in neutralizing buffer.
- Plate on appropriate agar and incubate under suitable conditions for recovery.
- Count colonies and compare to initial inoculum.
5.7 Acceptance Criteria
Comply with acceptance criteria as per USP <51>, EP or product-specific regulatory guidelines. For example:
- Bacteria: Not less than 2 log reduction at Day 14 and no increase thereafter.
- Fungi: No increase from initial count at any time point.
5.8 Documentation
- Record all data in PET Worksheet and Microbiology logbook.
- Attach raw data, microbial plates photographs (if required), and recovery charts to the report.
6. Abbreviations
- PET: Preservative Efficacy Testing
- CFU: Colony Forming Units
- USP: United States Pharmacopeia
- EP: European Pharmacopeia
7. Documents
- Preservative Efficacy Test Worksheet – Annexure-1
- PET Summary Report Template – Annexure-2
- Microbial Inoculum Preparation Record – Annexure-3
8. References
- USP <51> Antimicrobial Effectiveness Testing
- European Pharmacopeia – PET Guidelines
- WHO Guidelines on Pharmaceutical Microbiology
9. SOP Version
Version: 2.0
10. Approval Section
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Prepared By |
Checked By |
Approved By |
| Signature |
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| Date |
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| Name |
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| Designation |
Jr. Production Chemist |
QA Executive |
Head – Manufacturing |
| Department |
Gel Manufacturing |
Quality Assurance |
Manufacturing |
11. Annexures
Annexure-1: Preservative Efficacy Test Worksheet
| Sample Name |
Batch No. |
Organism |
Initial Count (Day 0) |
Day 7 |
Day 14 |
Day 21 |
Day 28 |
Remarks |
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Annexure-2: PET Summary Report Template
| Test Organism |
Log Reduction Day 14 |
Log Reduction Day 28 |
Complies with USP/EP |
Conclusion |
| E. coli |
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| S. aureus |
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| P. aeruginosa |
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| C. albicans |
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| A. brasiliensis |
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Annexure-3: Microbial Inoculum Preparation Record
| Date |
Organism |
Culture Media |
Harvest Method |
CFU/mL Achieved |
Prepared By |
Checked By |
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Revision History
| Revision Date |
Revision No. |
Details |
Reason |
Approved By |
| 05/06/2022 |
1.0 |
Initial Release |
New SOP |
QA Head |
| 02/06/2025 |
2.0 |
Updated structure and annexures |
Compliance Update |
QA Head |