MFR of Chlorpheniramine Maleate & Bromhexine hydrochloride Syrup

Chlorpheniramine Maleate & Bromhexine hydrochloride Syrup

PURPOSE:  This Master Manufacturing formula (MFR) is written to describe the formulae, manufacturing procedure, specifications, packing details of dosage form.

SCOPE: This MFR is performed and is applied during the manufacturing of dosage form.

RESPONSIBILITY / ACCOUNTABILITY: It is the responsibility of  Manufacturing Chemist to follow and adhere to this MFR. The Production Manager, QC/QA Manager are accountable for the strict adherence to the master Formula.

COPY ISSUED TO:

1. Master Copy : Manager Quality Assurance
2. Copy No. 1 : Production Manager
3. Copy No . 2 : Manager Quality Control
4. Copy No. 3 : Liquid Section

PRODUCT NAME: Chlorphenarmine  Maleate & Bromhexine hydrochloride Syrup	BATCH SIZE:  2000 LTRS.
PRODUCT REFERENCE CODE:	UNIT SIZE:  100 ML
GENERIC NAME: N.A.	PACK SIZE:  12 x 6 x 100 ml
DOSAGE FORM: SYRUP	STRENGTH: N.A.
DEPARTMENT:  LIQUID DEPARTMENT	EXPIRY DATE: AFTER 36 MONTHS     FROM THE DATE OF MANUFACTURING

COMPOSITION:

Each 5 ml contains:

Chlorpheniramine Maleate                B.P.      2 mg              Guaiphenesin                                       B.P.     50mg

Bromhexine hydrochloride               B.P.     4 mg              Dextromethorphan HBr                         B.P.         5 mg

EQUIPMENTS TO BE USED: 

SR. NO.	NAME OF EQUIPMENT	ASSEMBLING AS PER SOP NO.	CLEANING AS PER SOP NO.
1	Sugar Syrup Manufacturing Tank
2	Sugar Storage Tank
3	Charging Tank – V – 3500 Ltrs.
4	Filter Press
5	Storage Tank – III – 3500 Ltrs
6	Linear Bottle Washing Machine
7	Digipack Bottle Filling and Sealing Machine
8	Automatic Bottle Labelling Machine
9	Shrink Packing Machine

RAW MATERIAL:-

S.NO	INGREDIENTS	STD	Theoretical Quantity Req.	Overages %	Total Quantity Used
1.	BROMHEXINE HCL	B.P.	1.600	10.00	1.760 KGS
2.	ASPARTUM	B.P.	4.000		4.000 KGS
3	C.P.M	B.P.	0.800	10.00	0.880 KGS
4	BRONOPOL	B.P.	0.450		0.450 KGS
5	BRILLIANT BLUE COLOR	F.C.F	20.000		20.000 GMS
6	DEXTROMETHORPHAN HBR	B.P.	2.000	5.00	2.100 KGS
7	GUAIPHENESIN	B.P.	20.000	5.00	21.000 KGS
8	LIQUID GLUCOSE	B.P	400.00		400.00 KGS
10	MENTHOL	B.P.	0.900		0.900 KGS .200
11	ORANGE FLAVOUR	F.G	5.000		5.000 LTRS
13	P.G	B.P	45.960		45.960 KGS
14	BENZOIC ACID	B.P.	1.000		1.000 KGS
15	SPIRIT CHLOROFORM	B.P.	18.000		18.000 LTRS
16	TARTRAZINE SUPRA	FCF	0.100		0.100 GMS
17	PHARMA GRADE SUGAR	F.G	1400.00		1400.000 KGS

PACKING MATERIAL 

S.NO.	NAME OF THE MATERIAL	THEORETICAL QUANTITY REQ.	FOR RECORD	TOTAL QUANTITY USED
1.	100 ML AMBER ROUND BTLS	20000.000		20000.000 NOS
2.	ADHESIVE TAPE ROLL BROWN	3.000		3.000 NOS
3	LABEL	20278.333	3.000	20281.333 nos
4	UNIT CARTON	20000.000	2.000	20002.000 NOS
5	CORRUGATED BOX	278.333		278.333 NOS
6	GUM ACCACIA  POWDER	1.000		1.000 KGS
7	P. P. CAPS  25 MM(NEOMED)	20000.000		20000.000 NOS
8	INSERT	20000.00		20000.00 NOS.
9	SHRINK FILM 220 X 220 MM	3333.333		3333.333 NOS
10	MEASURING CUP	20000.00		20000.00 NOS

MANUFACTURING SPECIFICATION:

• Average fill of each Bottle is 100 ml.
• Volume variation limit allowed in each filled Bottle is 100 ml to 102 ml.
• Make up the final volume of the syrup accurately.
• Filter the completely charged batch using Filter Press L-21 by operating it as per its SOP.
• Transfer the syrup from charging tank L-10 to storage tank L-14 after complete charging of batch.
• Mix the batch, Fill the bottles and also perform the primary packing of bottles at temperature not more than 25⁰ C and Relative Humidity not more than 40.

Yield:

• Theoretical Yield is 20000 Bottles.
• Expected Practical Yield is 20000 +2% Bottles.

Packing Details:

• Wash the bottles on Linear Bottle Washing Machine L-24 and operate it as per its SOP.
• Transfer the Syrup from storage tank to Digipack Bottle Filling and Sealing Machine L-25 for filling and then Sealing of the bottles as per its SOP.
• Fill 100 ml syrup in White glass round bottle and use 25 mm PP Cap to seal the bottle mouth.
• Inspect the each filled and sealed bottle for proper sealing and presence of the foreign particles, if any.
• Label every inspected bottle by using the Automatic Bottle Labelling Machine L-26.
• Pack each filled and sealed bottle in unit carton individually.
• Make a group of 6 bottles packed in unit cartons.
• Wrap this bundle in the thermoplastic film and shrink pack it by operating Shrink Packing Machine L-27 as per its SOP.
• Pack such 12 shrinked packets in the Corrugated box. Thus each corrugated box contains 6 x 12 x 100 ml filled and sealed bottles. Seal each corrugated box with adhesive tape and label it properly by affixing the specified label.

MANUFACTURING PROCESS:

I) Preparation of Sugar Syrup:

• Take Purified water 450 Ltrs into Stainless Steel Steam Jacketed Sugar Syrup Preparation Tank.
• Run the steam into the jacket so as to heat the water.
• Add 1400 kgs of sugar into the tank and start stirring by operating the tank .
• Heat continuously till the sugar dissolves completely to give uniform Sugar Syrup.
• Transfer the prepared Sugar Syrup to Sugar Syrup Storage Tank through transfer pump.
• Transfer the 400 kgs Liquid Glucose to the Sugar Syrup Storage Tank and stir it vigorously for half an hour to dissolve it in the Sugar Syrup completely.
• Transfer the prepared Syrup from Sugar Syrup Storage Tank to Charging Tank  through transfer pump.

II) Addition of Ingredients into the Charging Tank L-10 while stirring continuously:

• Dissolve 1.0 kgs of Benzoic acid in 30 Ltrs of hot Purified water and add to the bulk batch.
• Dissolve 0.880 kgs of C.P.M in 4 Ltrs of Purified water and add to the bulk batch.
• Dissolve 4.00 kgs of Aspartum in 10 Ltrs of Purified water and add to the bulk batch.
• Dissolve 0.450 kgs of Bronopol in 3 Ltrs of water and add add to the bulk batch.
• Dissolve 1.760 kgs of bromhexine HCl and 21.00 kg Guaiphenesin in 45.906 kg of hot P.G and add to the bulk batch.
• Dissolve 2.1 kgs of Dextromethorphan HBr in 15 Ltrs of hot Purified water and add add to the bulk batch
• Dissolve 0.900 kgs of Menthol in 18ltrs of Spirit Chloroform and add to the bulk batch
• Dissolve 0.100 kgs of tartrazine Supra in 3 Ltrs of hot Purified water and add to the bulk batch.
• Dissolve 20 gms  of brilliant blue Colour in 1 Ltr of water and add add to the bulk batch.
• Add 8.0 Ltrs of Orange Flavour to the bulk batch.
• Make up the volume with DM water and mix until homogeneous.
• Check the pH of Solution to be in between 5.0 – 5.5.
• Filter the batch through Filter Press L-21 by operating it as per its SOP  and transfer it to the Storage Tank.
• Send the sample to Quality Control Department for bulk testing.

IN-PROCESS CONTROLS:

The following in-process controls should be maintained during the processing:

• Check Raw materials used for manufacturing purpose are all approved materials and have ‘Released’ labels fixed on it.
• All weighed Raw materials should be counter-checked by  Manufacturing Chemist. If any discrepancy is noticed, it should be immediately brought to the notice of Production Manager and QC/QA Manager.
• Physical characteristics of Raw material like colour, odour, and consistency are checked before compounding.
• Final volume should be made as per Standard Operating Procedure using correct dipstick in the Presence of  Manufacturing Chemist.
• pH of the bulk should be checked and it should be with in specified limits.
• Bulk sample should be sent for analysis to Quality Control Department before starting the filling and sealing stage.
• The  Manufacturing Chemist should check intermittently filled volume at 30 minutes interval and record for the same should be kept in Batch Manufacturing Record.
• The net volume should be checked for all the filling nozzles and in no case, net volume should be less than volume claimed on the label. 

   Limit for Volume Variation:  Volume claimed on the label + 2%

• Visual inspection of filled and sealed bottles should be done as per SOP and the record of the same should be kept in the Batch Manufacturing Record.
• Suspensions should be filled under constant slow speed stirring to maintain uniformity of contents.
• The labels and cartons should be checked thoroughly for proper batch coding.
• Intimation should be sent to Quality Control Department for finished product sampling and testing.
• After the completion of labelling and packaging, the coded labels and cartons should be accounted for and rejected printed material should be destroyed in the presence of QC/QA Manager. Maintain the destruction of the same in the Batch Manufacturing Record.
• It will be ensure that filling or packaging equipment has been properly cleaned.
• Filling or packaging of next product should not commence until the IPQA has given the ‘Line Clearance’.