Azithromycin 250 mg Tablets IP

Azithromycin 250 mg Tablets IP

TABLE OF CONTENTS 

S.NO.TITLEPage No.
1.0PRODUCT DETAILS
2.0MANUFACTURING FORMULA
3.0LIST OF EQUIPMENT
4.0GENERAL PRECAUTIONS
5.0MANUFACTURING INSTRUCTIONS
6.0

 

 

 

MANUFACTURING PROCESS DETAILS
6.1GRANULATION
6.2COMPRESSION
6.3COATING

1.0 PRODUCT DETAILS:

Product NameAzithromycin Tablets IP
Product DescriptionWhite color, round shape, biconvex, film-coated tablets  having both side plain
Strength250 mg
Label claim

 

Each film-coated tablet contains:

Azithromycin(As Dihydrate)

equivalent to Azithromycin Anhydrous – 250 mg

Batch Size2,00,000 Tablets
Average Weight347mg (Uncoated tablets)

354 mg (Film-coated tablets)

Shelf Life24 months
StorageStore in a cool, dry, and dark place below 250C
Drug CategoryMacrolide Antibiotics

2.0 MANUFACTURING FORMULA:

Material NameGradeCategoryQuantity per Unit (In mg)OveragesBatch Qty.

 (In kg)

Dry Mixing     
Azithromycin IPAPI250 mg5 %52.500 kg
MCCP PlainIPDiluent25 mg5.000 kg
Binder
PVPK-30IPBinder2.0 mg0.400 kg
Sodium  BenzoateIPPreservative0.7 mg0.140 kg
Sodium Starch GlycolateIPBinder10.00 mg2.000 kg
Purified WaterIPSolvent0.13 ml26.000 liter
Lubricant
TalcumIPAnti-caking agent7.0 mg1.400 kg
MCCP PH-102IPDiluent25 mg5.000 kg
Cross Carmellose SodiumIPDisintegrant7.0 mg1.400 kg
Crospovidone XLIPDisintegrant3.5 mg0.700 kg
AerosilIPGlidant1.5 mg0.300 kg
Calcium StearateIPAnti-Adherent3.5 mg0.700 kg

3.0 LIST OF EQUIPMENT:

Sr.No.Machinery/EquipmentCapacityEquipment ID.
1.Weighing Balance100 kg
2.Vibro Sifter

(with SS Sieves No’s 14,18,20, 40 , 60)

36 inch dia
3.Paste Kettle with stirrer100 liter
4.Portable Stirrer
5.Rapid Mixer Granulator (RMG)120 liter
6.Fluid Bed Dryer (FBD)120 kg
7.Multi Mill (screen size 2 mm and 8 mm)
8.Bin Blender150 liter
9.Halogen Moisture Balance
10.Compression Machine37 Station
11.SS Containers10 liter (02 No’s),

70 liter (01 No.)

100 liter (02 No’s)

12.Double Poly-lined HDPE Containers with lid45 liter( 08No’s)

65 liter (01 No.)

13.Polybags1.0 kg (03 No’s)

5.0 kg (01 No.),

10 kg (01 No.)

4.0 GENERAL PRECAUTIONS:

  • API Description Azithromycin: A White or almost white color powder. Protected from moisture during storage.
  • All the Manufacturing Activities shall be performed under controlled conditions (temperature NMT 25 0C and relative humidity NMT 60%).
  • When working with Active Ingredients and drug product or mixture of Active Ingredients and Excipients, wear gloves and mask to avoid exposure and contact with any body parts.

5.0 MANUFACTURING INSTRUCTIONS:

  • All activities shall be performed as per current SOPs.
  • Take the line clearance from QA before starting the manufacturing operation during batch to batch and product to product change over.
  • Do not overwrite the entry. In case of mistake, cancel the entry by single line with sign & date and make correct entry.

6.0 MANUFACTURING PROCESS DETAILS:

6.1 GRANULATION:

STEP – I (SIFTING):

  • Check Sieve Integrity (before and after sifting).
  • Set the Vibro Sifter (capacity: 36 inch dia) and sieve the Dispensed Materials as per Sieve Sizes mentioned below:
Material Name Std. Qty. (kg)Sieve No.
Dry Mixing
Azithromycin IP52.500 kg18 #
MCCP Plain IP5.000 kg60 #
Binder
PVPK-30 IP0.400 kg20
Sodium Benzoate IP0.140 kg20
Sodium Starch Glycolate IP2.000 kg60 #
Lubricant
Talcum IP1.400 kg60 #
MCCP PH-102  IP5.000 kg40 #
Cross Carmellose Sodium IP1.400 kg60 #
Crospovidone XL0.700  kg60 #
Aerosil IP0.300 kg14 #
Calcium Stearate IP0.700 kg60   #

 

  • Collect sifted Azithromycin IP (52.500 kg) and MCCP Plain IP (5.000 kg) in one Poly-lined HDPE Container (capacity: 65 liter).
  • Collect sifted PVPK-30 IP (0.400 kg) in one Polybag (capacity: 1.0 kg).
  • Collect sifted Sodium Benzoate IP (0.140 kg) in one Polybag (capacity: 1.0 kg).
  • Collect sifted Sodium Starch Glycolate IP (2.000 kg) in one Polybag (capacity: 5.0 kg).
  • Collect sifted Talcum IP (1.400 kg), MCCP PH-102 IP (5.000 kg), Cross Carmellose Sodium IP (1.400 kg), Crospovidone XL IP (0.700 kg), Aerosil IP (0.300 kg) in one Polybag (capacity:10 kg).
  • Collect sifted Calcium Stearate IP (0.700 kg) in one Polybag (capacity: 1.0 kg).

STEP – II (BINDER PREPARATION):

  • Take purified water (21.00 liter) in Paste Kettle (capacity: 100 liter), heat the purified water up to 350
  • Take purified water (3.000 liter, at temperature 350C) from Paste Kettle of Step-II(a) in SS Container (capacity: 10 liter) and add Sodium Benzoate IP (0.140 kg) and PVPK-30 IP (0.400 kg) and mix one by one with stirrer till dissolved properly in water and make a solution.
  • Heat the remaining purified water upto 800C of Step-II (a) (18.000 liter) in Paste Kettle.
  • Take purified water separately (5.000liter, at room temperature) in SS Container (capacity: 10 liter) and add Sodium Starch Glycolate IP (2.000 kg) slowly continuously stirring till uniform solution is ready.
  • Add above solution of Step – II (d) to heated purified water of Step -III (c) in Paste Kettle with continuously stirring till uniform paste is ready.
  • Add Step -II (b) solution with continuously stirring to Step-II (c) till final paste is ready.
  • Transfer the ready paste by tilting the Paste Kettle in one SS Container (capacity: 70 liter). Cool the paste upto 35°C to 40°C.

STEP – III (DRY MIXING):

Transfer the sifted Azithromycin IP and MCCP Plain IP in Rapid Mixer Granulator (capacity: 120 liter) running at slow speed impeller (0.82 ampere) and dry mix the materials till uniform mixing.

Mixing Time: 05 minutes.

Mixing Speed: 05 minutes at slow speed.

Ampere Load of Impeller: 0.82 ampere.

STEP –IV (BINDING OF DRY MIX MATERIAL):

Slowly add the binder of Step-II (g) in dry mix materials of Step -III in Rapid Mixer Granulator running at

slow speed impeller (1.02 ampere)for 05 minutes till binder addition. After binder addition run impeller and

chopper both at slow speed (0.63 ampere) for 05 minutes and finally run both impeller and chopper on fast

speed (0.97 ampere) for 02 minutes till uniform mixing. Unload the material in SS Container (capacity: 100

liter) from RMG by opening the discharge point with running impeller.

Mixing Time: 12 minutes

Ampere Load of Impeller: 0.62 to 1.02 ampere.(To be validated in next batch) 

STEP-V (WET SCREENING):

Check Screen Integrity (before and after screening).

Take wet material from SS Container and pass through Multi-Mill with screen size 8 mm and collect the

wet material in SS Container (capacity: 100 liter) and after that transfer the wet material in a FBD bowl.

STEP –VI (DRYING):

Dry the wet material of Step-V in FBD (capacity: 120 kg) until the LOD of granules is achieved between

  • to 1.5 % at 105°C checking by Halogen Moisture Balance and after drying unload the material in two

Poly-lined HDPE Containers (capacity : 45 liter each).

Inlet Temperature: 65°C

Outlet Temperature: 45°C

Raking Frequency: After 30 minutes.

Drying Time: 02 Hours.

STEP-VII (SIZING/MILLING):

Check Sieve & Screen Integrity (before and after sifting& screening).

Set the Vibro Sifter and fix the Sieve 18 # and sieve the dried material of Step-VI and collect in two Poly

lined HDPE Containers (capacity: 45 liter each) and remaining retention after sieving, pass through the

Multi-Mill using screen size 2 mm. After screening keep the screened material with sized material in above

Poly-lined HDPE Containers. Weigh and record the sized/milled granules quantity.

Blade Type: Both (Knife blades and Scraping blades).

Rotor Speed: 2000 RPM.

STEP – VIII (PRE –LUBRICATION):

Load the sized granules of Step-VII in Bin Blender (capacity: 150 liter) and add sifted Talcum IP,

MCCP PH-102 IP, Cross Carmillose Sodium IP, Crospovidone XL and Aerosil IP, mix properly till uniform

mixing of sized material with Pre-Lubricating Materials.

Mixing Time: 30 minutes (15 minutes clockwise direction and 15 minutes anti-clockwise direction).

Mixing Speed: 10 RPM.

STEP – IX (LUBRICATION):

Add the sifted Calcium Stearate IP in Pre- Lubricated Material of Step-VIII and mix properly till uniform

mixing of materials with Calcium Stearate IP.

Mixing Time: 05 minutes(clockwise direction)

Mixing Speed: 10 RPM.

STEP- X (BLEND SAMPLE ANALYSIS):

After completion of lubrication, collect the composite blend sample (Qty. 10 gm) and send to QC for

analysis according to the table below:

TestSpecification
Appearance of blend

Blend Uniformity

Blend Assay

LOD

Bulk Density

Tapped Density

Compressibility Index

Hausner Ratio

White free flowing granular powder

90 % to 110 %

95 % to 105 %

1.0 % to 1.5 %

0.6250 gm/ml

0.7500 gm/ml

16.667 %

1.2000

STEP – XI:

  • Take Tare Weight of two Double Poly-lined HDPE Containers (capacity: 45 liter each), record the Tare Weight in BMR and unload the above blended material from Bin Blender in Double Poly-lined HDPE Containers (capacity: 45 liter each) and weigh the material with containers and record the Gross Weight of the material and calculate the Net Weight of the material as per given formula:

Net Weight = Gross Weight – Tare weight

  • Affix the status label with following details – Product Name, Batch No., Batch Size, Mfg. Date, Exp. Date, Tare Weight, Gross Weight and Net Weight on the Poly-lined HDPE Containers.
  • Batch Yield of Lubricated granules:

Theoretical Batch Yield: 100 %

Actual Batch Yield Limit NLT 99 % (To be established in next batch)

STEP – XII:

  • Clean all equipments used in the granulation as per respective equipment cleaning SOP.

6.2 COMPRESSION:

STEP – I:

  • After receiving of QC approval for the blend, verify the Net Weight of the received blend as per status label in Granules Day Store.
  • Set the 37 stations (D-Tooling) Compression Machine. Compress the blend as per below parameters and In Process checks and take a sample for Dissolution (Qty. 20 tablets) and send to QC Department for Dissolution Analysis.
  • After confirmation of Dissolution result continue the compression with the blend as per the following parameters and In Process checks under controlled environmental condition.
Sr.No.ParametersStandardNo. of TabletsIn-Process Frequency
1.       Feed frame alignment and adjustmentShould be satisfactory—–—–
2.       Lower Weight AssemblyShould be satisfactory—–—–
3.       Hydraulic Pressure6-8 Tones—–—–
4.       Machine Speed18 RPM -20 RPM—–—–
6.       Upper Punch Size11 mm­—–—–
7.       Lower Punch Size11 mm—–—–
8.       Avg.- Diameter11 mm6/Individual2 hours
9.       Thickness of Tablets3.70 mm ±.2 mm6/Individual2 hours
10.   Weight of 20 Tablets6.940 gm. ± 3%20/Composite   30 minutes
11.   Tablets for Dissolution347 mg ± 2%20/CompositeBefore starting    the Compression
12.   DissolutionNLT 80 %—-—-
13.   Product DescriptionWhite , round biconvex, uncoated tablets having both side plain20/Composite  30 minutes
14.   Uniformity of WeightNMT 02 tablets out of 20 deviate from the standard average weight by more than 3 % and  no single tablet deviates from the standard average weight by more than 5 %20/Composite01 hour
15.   Standard Average Weight of Tablets347 mg ± 2 %20/Individual  30 minutes
16.   HardnessNLT 3 kg/cm26/Individual  30 minutes
17.   Disintegration TimeNMT 15 min6/Composite01 hour
18.   FriabilityNMT 1%20/Composite01 hour
  • Collect the compressed tablets in Double Polylined SS Container (capacity: 20 liter each on both sides), when SS containers are filled with tablets, transfer the tablets in two Poly-lined HDPE Containers as given in below Step-III.

STEP – II:

  • Send the composite sample of compressed tablets (Qty. 30 tablets) to QC department for analysis.

STEP – III:

  • Take Tare Weight of two Double Poly-lined HDPE Containers (capacity: 45 liter each), record the Tare Weight in BMR and transfer the compressed tablets in Poly-lined HDPE Containers (capacity: 45 liter each) and weigh the compressed tablets with containers and record the Gross Weight of the compressed tablets and calculate the Net Weight of the material as per given formula:

Net Weight = Gross Weight – Tare weight

  • Affix the status label with following details – Product Name, Batch No., Batch Size, Avg. Weight, Mfg. Date, Exp. Date, Tare Weight, Gross Weight and Net Weight on the Poly-lined HDPE Container.
  • Batch Yield of Compressed Tablets:

Theoretical Batch Yield: 100 %

Actual Batch Yield Limit NLT 99 % (To be established in next batch) 

STEP – IV:

  • After completion of compression clean the Compression Machine as per cleaning SOP.

 6.3 COATING:

  • Verify the Net Weight of the received compressed tablets for coating as per status label and after

confirmation continue for tablet coating.

STEP – I (COATING MATERIALS DETAILS):

Sr. NoMaterial NameBatch Quantity
1.Film Coat Aqua White Powder1.388 kg.
2.Purified Water IP12.042 liter

 STEP-II (LIST OF EQUIPMENTS FOR COATING):

Sr. No.Machineries/EquipmentsCapacityEquipment ID.
1.Auto coater48″
2.Spray Gun03
3.Filter Cloth 100 #0.5 mm
4.Portable Stirrer
5.SS Containers15 liter (02 No’s)
6.Double Poly-lined HDPE Containers with lid45 liter (02 No’s)

STEP – III (PREPARATION OF COATING SOLUTION):

  • Take Purified Water IP (12.042 liter, at room temperature) in SS Container (capacity: 15 liter) and add Film Coat Aqua White Powder (1.388 kg) and mix together by Portable Stirrer continuously stirring  till uniform mixing achieved.

Speed of stirrer: Constant.

Mixing Time: 15 minutes.

  • Filter the coating solution with Filter Cloth 100 # in one SS Container (capacity: 15 liter).
  • Keep the solution for 15 minutes to let the foam settled down. Thereafter transfer the coating solution in SS tank and proceed with coating process.

STEP – IV (COATING PROCEDURE FOR FILM COATING):

  • Coating will be done in one lot (for 2,00,000 tablets), take total compressed tablets for coating (69.400 kg).
  • Start the pan, inlet damper and then start exhaust blower to maintain the bed temperature by press the heater “ON” position.
  • Press the hot air blower switch to start the hot air blower.
  • Start the coating pan and adjust the distance between tablet bed and gun and introduce the spray gun assembly into the coating pan
  • Load the tablets in Auto coater (Capacity: 48″), start the hot air blower, set the inlet air temperature at 70°C to 75°C and start the exhaust fan & warm the tablets bed 40°C to 45°C.
  • After warming the tablets, take weight of 100 warmed tablets and record the weight in BMR for calculation of weight buildup of tablets after coating.
  • Set the coating parameter as given in below table and start the coating process by starting coating spray through gun.
ParameterSpecification
No. of Baffles in coating pan—-
No. of Guns03
Inlet Temperature70°C to 75°C
Peristaltic Pump Speed2- 4 RPM
Atomization2.5 to 3.0 kg/cm2
Gun to Tablet Bed Distance7  to 10 cm
BED Temperature400C to 45 0C
Pan RPM13 to 15 RPM
% Weight Gain

 (1.5 % to 2.0 %)

Weight of Film-Coated Tablets – Weight of Uncoated Tablets x 100

                          Weight of Film-Coated Tablets

Coating Time2 Hours
  • After completion of Film coating, take weight of 100 Film coated tablet and record the weight in BMR and calculated the weight gain by using Weight Gain Formula given in above table of Step-IV.

STEP – V (COATING IN-PROCESS CHECK PARAMETERS):

  • After completion of coating perform the In Process checks as per below parameters:
Sr.No.ParametersStandardNo. of TabletsIn-Process Frequency
1Product DescriptionWhite, round biconvex, film coated tablet having both side plain20 No. 

 

 

After batch completion

2Weight of 20 Tablets after coating7.080 gm. (+2 % Weight Gain)20 No.
3Average Weight after coating354 mg (+2 % Weight Gain)20 No.
4Individual Tablets Weight VariationNMT 02 tablets out of 20 deviate from the standard average weight by more than 3 % and  no single tablet deviates from the standard average weight by more than 5 %20 No.
5Thickness3.71 mm ± 0.2 mm6 No.
6DisintegrationNMT 30 min.6 No.

STEP – VI:

  • Send the Composite sample of coated tablets (Qty. 50 tablets) to QC department for analysis. 

STEP – VII:

  • Take Tare Weight of two Double Poly-lined HDPE Containers (capacity: 45 liter each), record the Tare Weight in BMR and transfer the coated tablets in Double Poly-lined HDPE Containers (capacity: 45 liter each) and weigh the coated tablets with containers and record the Gross Weight of the coated tablets and calculate the Net Weight of the material as per given formula:

Net Weight = Gross Weight – Tare weight

  • Affix the status label with following details – Product Name, Batch No., Batch Size, Avg. Weight, Date, Exp. Date, Tare Weight, Gross Weight and Net Weight on the Poly-lined HDPE Containers.
  • Batch Yield of Coated Tablets:

Theoretical Batch Yield: 100 %

Actual Batch Yield Limit NLT 99 % (To be established in next batch).

 

About ABHA

Abha is the Author  of pharmaceutical guidance, she is a pharmaceutical professional having more than 22 years of rich experience in pharmaceutical field. During her career, she works in the quality assurance department with multinational companies i.e Zydus Cadila Ltd, Unichem Laboratories Ltd, Indoco remedies Ltd. During his experience, she faces many regulatorily audits i.e. USFDA, MHRA, ANVISA, MCC, TGA, EU –GMP, WHO –Geneva, ISO 9001-2008 and many ROW Regularities Audit i.e.Uganda, Kenya, Tanzania, Zimbabwe. She is currently leading a regulatory pharmaceutical company as a Head Quality. You can join him by Email, Facebook, Google+, Twitter, and YouTube

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