MASTER FORMULA OF FOOT CARE CREAM

MASTER FORMULA OF FOOT CARE CREAM

PURPOSE: This Master Formula is written to describe the formulae, manufacturing procedure, specifications, packing details of dosage form.

SCOPE: This procedure 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 SOP. The Production Pharmacist, 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 Pharmacist

3. Copy No.  2:      Manager Quality Control

4.  Copy No. 3:      Ointment Section 

PRODUCT NAME: FOOTCARE CREAM BATCH SIZE:  300 KG
PRODUCT REFERENCE CODE: O-19 UNIT SIZE:  25g
GENERIC NAME: N.A. PACK SIZE:  30 ´ 12 ´ 25g
DOSAGE FORM: OINTMENT STRENGTH: N.A.
DEPARTMENT:  OINTMENT DEPARTMENT EXPIRY DATE: AFTER 24 MONTHS  FROM THE DATE OF MANUFACTURING

 COMPOSITION: 

Urea I. P. 10% w/w
Lactic Acid I. P. 10% w/w
Propylene Glycol I. P. 10% w/w
Liquid Paraffin I. P. 10% w/w

  SPECIMEN UNIT CARTON : 

  EQUIPMENTS TO BE USED: 

SR. NO. NAME OF EQUIPMENT ASSEMBLING

AS PER SOP NO.

CLEANING

AS PER SOP NO.

1 Wax Vessel
2 Water Vessel
3 Mixing Vessel
4 Colloidal Mill
5 Storage Container-I (500 Kg)
6 Semiautomatic Tube Filling & Sealing Machine

 RAW MATERIALS:-

S.NO. INGREDIENTS STD Theoretical Quantity Req. Overages % Total Quantity Used
1. CETO MACROGOL  – 1000 I.P. 3.000 KG 3.000 KG
2. CETOCETYL ALCOHOL I.P. 6.000 KG 6.000 KG
3 LACTIC ACID I.P. 30.000 KG 13.34 34.002 KG
4. LIQUID PARAFFIN LIGHT I.P. 30.000 KG 30.000 KG
5 METHYL PARABEN (PLAIN) I.P. 0.300 KG 0.300 KG
6 PEG – 4000 I.P. 103.000 KG 103.000 KG
7 PEG – 400 I.P. 65.000 KG 65.000 KG
8 P.G. I.P. 30.000 KG 30.000 KG
9 PROPYL PARABEN (PLAIN) I.P. 0.150 KG 0.150 KG
10 UREA I.P. 30.000 KG 30.000 KG

 PACKING MATERIALS: –

S.NO. NAME OF THE MATERIAL THEORETICAL QUANTITY REQ. FOR

RECORD

TOTAL QUANTITY USED
1. ADHESIVE TAPE ROLL 1.000 1.000 NOS
2 CELLO TAPE 1.000 1.000 NOS
3 CORRUGATED BOX 33.000 33.000 NOS
4 PLASTIC TUBES 12.000.00 12000.00 NOS
5 UNIT CARTON 12000.000 3.00 12003.00 NOS
6 OUTER CARTON 1000.000 2.00 1020.00 NOS

 MANUFACTURING SPECIFICATIONS: 

1.     Average fill of each Tube is 25 grams.

2.     Weight variation limit allowed in each filled Tube is + 200 mg.

3.     Melt the waxes at the maintained temperature 70˚ C.

4.     Colloid the cream till uniform particle size is achieved.

5.     The temperature of primary area should not exceed 30˚C.

 Yield:

· Theoretical Yield is 12000 Tubes.

· Expected Practical Yield is 12000 + 2% Tube.·

 Packing Details:

1. Transfer the cream from storage tank to Semiautomatic Lami Tube Filling & Sealing Machine and start filling and then sealing of the tubes as per its SOP.

2.Pack the filled tubes in unit cartons.

3.Pack such 12 tubes in each outer carton.

4.Seal the outer carton with cello tape.

5.Pack the 30 outer cartons in specified corrugated box D-17 to give a pack size of 30 x 12 x 25g tubes.

6.Seal each corrugated box with adhesive tape and label it properly by affixing the specified label.

 MANUFACTURING PROCESS: 

1. Melt 3.0 kg of Ceto Macrogol- 1000, 6.0 kg of Cetocetyl Alcohol, 30 kg of Liquid Paraffin Light and 103 kg of PEG-4000 in a Steam Heat Wax Melting Vessel by operating it as per its SOP at temperature 70˚C.

2.Heat 20 .0 kg of PEG- 400 and transfer it to the mixing vessel after filtering it.

3.Filter and transfer the melted base through Stainless Steel Sieve no. 100 to the mixing vessel and start the machine.

4. Heat 3.0 kg of PG to 60˚ C and dissolve 0.300 kg of Methyl Paraben and 0.150 kg of Propyl Paraben in it and transfer it to the bulk batch.

5.Take 34.002kg of Lactic Acid, 45.0 kg of PEG-400 and 27.0kg of PG. Add 30.0kg of urea to it gradually and pass it through Colloid Mill to achieve the slurry of   uniform particle size by operating it as per its SOP and transfer it to the bulk batch.

6.Cool the cream to the room temperature by running the water in the jacket of Mixing Vessel.

7.Mix the whole batch for 4.5 hours.

8.Send the sample to Quality Control Department for bulk testing.

9. After approval from Quality Control Department, transfer the cream to the storage tank. 

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  and QC/QA Manager.

Physical characteristics of Raw material like colour, odour, and consistency are checked before compounding.

The total weight of bulk ointment / cream should be checked in the presence of Assistant Manufacturing Chemist and record the same in Batch Manufacturing Record.

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.

While the tube filling operation is on, the Assistant Manufacturing Chemist should check weight of net filled quantity per tube at the interval of 30 minutes by checking the tare weight of empty tube and gross weight of the filled tube. Record for the same should be kept in Batch Manufacturing Record.

The ‘fill weight’ of ointment or cream per tube should not be less than the labelled amount.

 Limit for Weight Variation:  Weight claimed on the carton + 200 mg

Manufacturing Chemist will also ensure that the crimping of the filled Aluminum tubes, sealing of plastic tubes is appropriate and embossing of batch number and manufacturing date is conspicuous. Also the quality of embossing will be controlled by adjusting pressure exerted by the jaws, so that pinholes are not developed on the embossed letters / numbers.

The inner and outer cartons should be checked thoroughly for proper batch coding.

Manufacturing Chemist and Production Pharmacist should randomly check that the correct no. of inner cartons are being packed in each outer cartons and also the correct number of outer cartons in each shipper is exactly the same as that shown in proof.

Intimation should be sent to Quality Control Department for finished product sampling and testing.

After the completion of filling and packaging, the coded 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 be commenced only after getting the ‘Line Clearance’ of the previous product, from the IPQA.

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