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Sterile Injectable Manufacturing: SOP for Spectroscopic Analysis of Injectable Solutions – V 2.0

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Sterile Injectable Manufacturing: SOP for Spectroscopic Analysis of Injectable Solutions – V 2.0

Standard Operating Procedure for Spectroscopic Analysis of Injectable Solutions


Department Sterile Injectable Manufacturing
SOP No. SOP/SIM/163/2025
Supersedes SOP/SIM/163/2022
Page No. Page 1 of 14
Issue Date 24/06/2025
Effective Date 26/06/2025
Review Date 24/06/2026

1. Purpose

This SOP defines the standardized procedure for performing spectroscopic analysis—specifically UV-Vis, FTIR, and Near Infrared (NIR) spectroscopy—on sterile injectable solutions to evaluate their identity, concentration, and purity according to GMP and ICH guidelines.

2. Scope

This SOP applies to the Quality Control (QC) department

involved in analytical testing of all injectable solutions produced at the manufacturing site. It includes the usage of spectroscopic techniques for both in-process and finished product analysis.

3. Responsibilities

  • QC Analyst: Perform and document the spectroscopic analysis.
  • QC Supervisor: Review and verify analytical data.
  • QA Officer: Ensure compliance with procedures and approve results.
  • Instrument Technician: Maintain and calibrate spectroscopic instruments.

4. Accountability

The Head of Quality Control is accountable for implementation and execution of this SOP.

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5. Procedure

5.1 Types of Spectroscopic Techniques

  1. UV-Visible Spectroscopy: For quantitative analysis and impurity detection.
  2. FTIR (Fourier Transform Infrared Spectroscopy): For identification of functional groups and compatibility studies.
  3. NIR (Near Infrared Spectroscopy): For rapid, non-destructive testing, typically used in PAT applications.

5.2 Instrumentation

  • UV-Vis Spectrophotometer (range 190–800 nm)
  • FTIR Spectrometer with ATR module
  • NIR Spectrometer with fiber optic probe
  • Computer with validated software (e.g., UVProbe, Spectrum, Vision)

5.3 Sample Preparation

  1. Ensure sample is clear and free of particulates. Filter if needed using 0.22 µm filter.
  2. Use appropriate blank solution (e.g., Water for Injection, diluent).
  3. Prepare standard solutions according to the method SOP.
  4. Label all sample cuvettes or vials appropriately.

5.4 Method of Analysis

5.4.1 UV-Visible Analysis

  1. Switch on UV-Vis system and allow warm-up (typically 30 min).
  2. Run baseline with blank.
  3. Scan standard and sample from 200–400 nm as applicable.
  4. Record absorbance at specified λmax for quantitative results.
  5. Use Beer’s Law for concentration determination.

5.4.2 FTIR Analysis

  1. Ensure the ATR crystal is clean and dry.
  2. Place a few drops of liquid sample on the crystal.
  3. Record the IR spectrum in 4000–400 cm⁻¹ range.
  4. Compare with reference spectrum for identity verification.
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5.4.3 NIR Analysis

  1. Use pre-calibrated model if available.
  2. Position the fiber probe into the sample vial.
  3. Scan over 1000–2500 nm range.
  4. Obtain spectral match or quantitative readout from software.

5.5 Acceptance Criteria

  • Spectrum should match the reference standard (≥ 90% match).
  • Absorbance readings must fall within the validated range.
  • Deviation in spectra must be investigated and documented.

5.6 System Suitability

  1. Run system suitability standard before sample analysis.
  2. Ensure baseline drift, resolution, and absorbance fall within limits.

5.7 Data Handling and Reporting

  1. Save raw data electronically with secure access control.
  2. Print and review spectral overlay and results.
  3. Record all observations in Annexure-1: Spectroscopy Test Data Sheet.

5.8 Cleaning and Shutdown

  1. Clean cuvettes or ATR crystals with methanol or suitable solvent.
  2. Switch off instrument as per manufacturer’s SOP.
  3. Log usage and shutdown time in instrument usage log.

6. Abbreviations

  • SOP: Standard Operating Procedure
  • QC: Quality Control
  • QA: Quality Assurance
  • UV: Ultraviolet
  • IR: Infrared
  • NIR: Near Infrared
  • FTIR: Fourier Transform Infrared Spectroscopy
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7. Documents

  1. Spectroscopy Test Data Sheet – Annexure-1
  2. Spectral Comparison Report – Annexure-2
  3. Instrument Usage Log – Annexure-3

8. References

  • ICH Q2(R1): Validation of Analytical Procedures
  • USP General Chapters <857>, <858>, <1856>
  • Instrument Manufacturer’s User Manual

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation QC Analyst QA Executive Head QA
Department Quality Control Quality Assurance Quality Assurance

11. Annexures

Annexure-1: Spectroscopy Test Data Sheet

Sample ID Type λmax (nm) Absorbance Status
INJ325 UV 276 0.582 Pass

Annexure-2: Spectral Comparison Report

Sample ID Reference Match (%) Result Analyst
INJ325 96.2% Complies Anjali Desai

Annexure-3: Instrument Usage Log

Date Instrument Start Time End Time User
24/06/2025 FTIR-01 09:00 11:00 Ravi Kumar

Revision History:

Revision Date Revision No. Details Reason Approved By
10/01/2022 1.0 Initial Release New Procedure QA Head
24/06/2025 2.0 Updated to include NIR procedures and new annexures Annual SOP Review QA Head
Injectables V 2.0 Tags:Aseptic processing SOP, Aseptic technique in sterile manufacturing, Cleanroom SOP for injectables, SOP for ampoule sealing, SOP for autoclave sterilization, SOP for container closure integrity testing, SOP for environmental monitoring in aseptic area, SOP for gowning in cleanroom, SOP for in-process checks in sterile manufacturing, SOP for injectable formulation, SOP for lyophilizer operation, SOP for sterile filtration, SOP for sterilization validation, SOP for vial filling, SOP for visual inspection of injectables, Sterile area cleaning SOP, Sterile filling line SOP, Sterile injectable quality control SOP, Sterile injection SOP, Sterile manufacturing procedure

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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
  • Drug Discovery
  • Environment, Health and Safety
  • Formulation Development
  • Gels
  • Good Distribution Practice
  • Good Warehousing Practices
  • In-Process Control
  • Injectables
  • Liquid Orals
  • Liposome and Emulsion Formulations
  • Lotions
  • Lyophilized Products
  • Maintenance Dept.
  • Medical Devices
  • Metered-Dose Inhaler
  • Microbiology Testing
  • Nanoparticle Formulation
  • Nasal Spray Formulations
  • Nebulizers
  • Ocular (Eye) Dosage Forms
  • Ointments
  • Otic (Ear) Dosage Forms
  • Pharmacovigilance
  • Powder & Granules
  • Purchase Departments
  • Quality Assurance
  • Quality Control
  • Raw Material Stores
  • Regulatory Affairs
  • Tablet Manufacturing
  • Rectal Dosage Forms
  • Transdermal Patches
  • Vaginal Dosage Forms
  • Validations and Qualifications

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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
  • Gels V 2.0
  • Injectables 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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