MFR of Alfacalcidol & Calcium Carbonate Tablets
MFR of Alfacalcidol & Calcium Carbonate
PURPOSE: This Master Formula Record 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 SOP. The Production Pharmacist, QC/QA Manager are accountable for the strict adherence to the master formula.
COPY ISSUED TO:
- Master Copy: Manager Quality Assurance
- Copy No. 1: Production Pharmacist
- Copy No. 2: Manager Quality Control
- Copy No. 3: Tablet Section
| PRODUCT NAME: Alfacalcidol & Calcium Carbonate | BATCH SIZE: 50,000 |
| PRODUCT REFERENCE CODE: | UNIT SIZE: 5 x 10 |
| GENERIC NAME: N.A. | PACK SIZE: 100 x 5 x 10 |
| DOSAGE FORM: TABLET | STRENGTH: N.A. |
| DEPARTMENT: TABLET DEPARTMENT | EXPIRY DATE: AFTER 24 MONTHS FROM THE DATE OF MANUFACTURING |
COMPOSITION:
Each film coated Tablet contains:
Alfacalcidol 0.25 mcg
Calcium Carbonate I.P. 500 mg
(Oyster Shell equ. to elemental Calcium 200 mg)
EQUIPMENTS TO BE USED:
| SR. NO. | NAME OF EQUIPMENT | ASSEMBLING AS PER SOP NO. | CLEANING AS PER SOP NO. |
| 1 | Steam Jacketed Starch Paste Preparation Tank | ||
| 2 | Sifter Machine – I | ||
| 3 | Roto Cube Blender –I | ||
| 4 | Rapid Mixer Granulator | ||
| 5 | Multi Mill | ||
| 6 | Fluidized Bed Drier | ||
| 7 | Oscillating Granulator | ||
| 8 | Sifter Machine – II | ||
| 9 | Roto Cube Blender – II | ||
| 10 | Tablet Compression Machine 20 Stations | ||
| 11 | Dedusting Machine | ||
| 12 | Colloid Mill | ||
| 13 | Tablet Inspection Machine | ||
| 14 | Rapid Cota Tablet Coating Machine | ||
| 15 | Single Track Blister Packing Machine |
RAW MATERIAL:-
| S.NO. | INGREDIENTS | STD | Theoretical Quantity Req. | Overages % | Total Quantity Used |
| 1. | Alfacalcidol | B.P. | 12.5000 | 12.500 mg. | |
| 2. | Calcium Carbonate | B.P. | 25.000 | 10.00 | 27.500 kg. |
| 3. | Di Calcium Phosphate | I.P. | 4.000 | 4.000 kg. | |
| 4. | ISO Propyl Alcohol | I.P | 7.500 | 7.500 kg. | |
| 5. | Instacoat White | I.P. | 0.700 | 0.700 kg. | |
| 6. | Lactose | I.P. | 1.500 | 1.500 kg. | |
| 7. | M.C.C.P | I.P. | 5.000 | 5.000 kg. | |
| 8. | Magnesium Stearate | I.P. | 0.150 | 0.150 kg. | |
| 9. | Methylene Chloride | I.P. | 13.000 | 13.000 kg. | |
| 10. | PVPK – 30 | I.P. | 0.250 | 0.250 kg. | |
| 11. | Sodium Benzoate | I.P. | 0.250 | 0.250 kg. | |
| 12. | Starch | I.P. | 3.000 | 3.000 kg | |
| 13. | Starch | I.P. | 2.500 | 2.500 kg. | |
| 14. | Starch | I.P. | 1.000 | 1.000 kg. | |
| 15. | Talcum | I.P. | 0.500 | 0.500 kg. |
PACKING MATERIAL:-
| S.NO. | NAME OF THE MATERIAL | THEORETICAL QUANTITY REQ. | FOR RECORD | TOTAL QUANTITY USED |
| 1. | 92 MM MILKY PVC | 7.000 | 7.000 KG | |
| 2. | ADHESIVE TAPE ROLL BROWN | 1.000 | 1.000 NOS | |
| 3. | ALUMINIUM FOIL | 1.500 | 1.500 KG | |
| 4 | CELLO TAPE | 1.000 | 1.000 NOS | |
| 5 | UNIT CARTON (1 X 10) | 5000.000 | 2.000 | 5002.00 NOS |
| 6 | OUTER CARTON (5 X 10) | 1000.000 | 2.000 | 1002.000 NOS |
| 7 | CORRUGATED BOXES | 10.000 | 10.000 NOS |
MANUFACTURING SPECIFICATION:
Moisture content of powder should be less than 2.0 %.
Average weight of each Tablet is 925 milligrams.
Weight Variation Limit for average weight of 20 tablets is +0 %.
Friability limit for 10 Tablets is not more than 1.0 %.
Hardness of the Tablets varies between 4-6 kg/cm2.
Disintegration time for each Tablet is not more than 30 minutes.
Mix the batch, compress and de-dust the tablets and also perform the primary packing of Tablets at temperature not more than 25˚ C.
Perform the coating of the tablets at temperature not more than 25˚ C and humidity not more than 40%.
Yield:
Theoretical Yield is 50,000 Tablets.
Expected Practical Yield is 50,000 + 2% Tablets.
Packing Details:
Use PVC 84 mm transparent and Aluminium foil for blister packing.
Blister Pack the inspected and coated tablets by using Single Track Blister Packing Machine as per its SOP.
Put 1 strip each containing 10 tablets in each inner carton.
Put such 5 inner cartons in each outer carton.
Seal each outer carton from both ends with cello tape.
Pack 100 outer cartons in specified corrugated box S-11 to give a pack size of 100 x 5 x 10 tablets.
Seal each corrugated box with adhesive tape and label it properly by affixing the specified label.
MANUFACTURING PROCESS:
Preparation of Starch Paste:
Prepare the starch paste in the manner given below using Steam Jacketed Starch Paste Preparation Tank by operating it as per its SOP Dissolve 0.250 kg of Sodium Benzoate in 1Ltr of DM water and stir continuously.
Add 1.0 kg of Starch in 2 Ltrs DM water and stir continuously to make smooth slurry.
Take 16 Ltrs of boiling water add the solution of sodium benzoate and starch slurry with constant stirring to get a uniform paste
Sifting:
Fit Stainless Steel Sieve #40 on the Sifter-I as per its SOP. Sift all the ingredients through it and collect separately in Stainless Steel Containers.
Blending:
Blend the following ingredients using Roto Cube Blender by operating it as per its SOP for 15 minutes and collect in Stainless Steel Container.
- 5.000 kg of M.C.C.P.
- 1.500 kg of Lactose.
- 3.0 kg of Starch.
- 4.00 kg of Di Calcium Phosphate.
- 27.50 kg of Calcium Carbonate
Wet Granulation:
Mix the above blended ingredients with the Starch paste using Rapid Mixer Granulator by operating it as per its SOP Add starch paste in such a manner by following the procedure given below so as to achieve proper wetting.
Mix the blended powder and starch paste together in Rapid Mixer Granulator.
Wet Screening:
Pass the wet dough through a Multi Mill by operating it as per its SOP to convert the moist mass into coarse, granular aggregates.
Drying:
Dry the granules in Fluidized Bed Drier by operating it as per its SOP at temperature 600 – 700 C for 45 minutes. Cool the granules to room temperature.
Sifting:
Fit Stainless Steel Sieve # 20 on the Sifter-II as per its SOP. Sift all the ingredients through it and collect in Stainless Steel Container. Break the oversized granules left over the mesh in Oscillating Granulator by operating it as per its SOP and resift them.
Check the total weight of dried granules. Determine the loss on drying and percentage yield of dried granules.
Lubrication:
Dissolve 12.5 mg of Alfacalcidol in 100 ml Spirit Chloroform. Then mix it in geometric proportion with 2.5kg of Starch properly in double polythene bag manually.
Now add the following lubricating agents to the Roto Cube Blender and operate it as per SOP for 45 minutes. Collect the blended powder in Stainless Steel Container:
- 0.500 kg of Talcum
- 0.150 kg of Magnesium Stearate
- Mixture of Starch and Alfacalcidol
Send the granules for bulk testing to Quality Control Department for assay of Active Ingredients.
Compression:
Shift all the granules for compression to Tablet Compression Machine 20 Stations by operating it as per its SOP and collect the compressed tablets in Stainless Steel Container.
Inspection:
Transfer all the tablets to tablet inspection machine and sort out the defected tablet by operating it as per its SOP and collect the selected tablets in Stainless Steel Container.
Coating of the tablet:
Dissolve 0.700 kgs of Instacoat white in 7.5 kgs of Isopropyl Alcohol. Then add 13.0 kgs of Methylene chloride to this solution. Collide the solution by colloidal mill as per its SOP No. SOP, Now start coating of the tablets by using Rapid Cota Tablet Coating Machine by operating it as per its SOP and collect the coated tablets in Stainless Steel Container.
Tablet Inspection:
Transfer all coated tablets to tablet inspection machine and sort out the defected tablet by operating it as per its SOP and collect the selected tablets in Stainless Steel Container.
Blister Packing:
Shift the inspected tablets to blister section and blister pack them using Single Track Blister Packing Machine by operating it as per its SOP.
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 Pharmacist and QC/QA Manager.
Physical characteristics of Raw material like colour, odour, and consistency are checked before compounding.
Humidity and temperature should be maintained during the compression of thermo labile products.
Sample of dried granules should be sent to Quality Control Department for the determination of Moisture content.
The total weight of blended powder should be checked in the presence of Assistant Manufacturing Chemist and record the same in Batch Manufacturing Record.
Bulk sample should be sent for analysis to Quality Control Department before starting compression of tablets.
Weight Variation: I) Intermittently weight variation of compressed tablets should be checked at 30 minutes interval by the Assistant Manufacturing Chemist and record for the same should be kept in Batch Manufacturing Record.
Out-of-limit tablets should be checked by Weight Variation Method as given below:
Take the average weight of 20 tablets on the calibrated balance and calculate the upper and lower limit as per the table given below in accordance with IP/BP:
| AVERAGE WEIGHT OF TABLETS (in mg) | MAXIMUM PERCENTAGE DIFFERENCE ALLOWED |
| 80mg or less | 10 |
| More than 80mg and less than 250mg | 7.5 |
| 250mg or more | 5 |
Take the weight of individual tablets and check if all the tablets are lying with in the limits.
Select the tablets only if no more than two tablets are out of percentage limit and if no tablet differs by more than two times the percentage limit, otherwise reject the tablets.
Adjust the desired weight of the tablets in the Compression Machine by moving weight adjustment cam clockwise or anticlockwise accordingly as per the Standard Operating Procedure of Compression Machine.
Re-check the weight of tablets for further adjustment, if any.
Thickness of Tablets:
Thickness of the tablets should be determined by means of the vernier caliper. The thickness of the tablet should be checked whenever weight adjustments are made.
Hardness of the tablets:
The equipment used is the ‘Monsanto’ type hardness tester. Hardness of the compressed tablets should be checked at regular interval to determine the need for pressure adjustments on the tableting machine.
Hardness of tablets varies between: 4-6 Kg/cm2.
Friability:
‘Roche Friabilator’ is used for measuring the Friability. The instrument is designed to evaluate the ability of the tablet to withstand abrasion in packaging, handling and shipping.
Adjust the instrument to 25 RPM before adding the tablets.
Weigh 20 Tablets on calibrated balance. Transfer the tablets in the plastic chamber. Close the drum tightly.
Switch on the apparatus. Operate the Friabilator for 100 revolutions.
De-dust and reweigh the tablets. Loss in weight indicates the ability of tablets to withstand the wear.
Take 10 tablets to check the friability, when the average weight of tablet is 1g or more than 1g.
Friability Limit = Less than 1.0%
Disintegration Test:
Disintegration is the time required for the group of tablets to disintegrate into the particles. Disintegration Test should be carried out at regular interval of 1 hour by using Disintegration Test Apparatus.
The tube assembly unit is removed from the glass beaker and from each tube the plastic discs are removed.
Place the tablets in each of 6 tubes along with a plastic disc over the tablets.
The glass beaker is filled with water. The water in the beaker is retained at the temperature of 37+1˚C through out the test by suitably setting the thermostat.
Introduce a tube assembly unit into glass beaker in such a way that wire mesh at the base of each tube is at least 2.5cm below the surface of liquid when the basket is at highest position.
Switch on the apparatus to move the basket assembly containing the tablets up and down through a distance of 5 to 6 cm at a frequency of 28 to 32 cycles per minute. Start the stopwatch.
When the tablets have disintegrated i.e. when no particles remain on the wire mesh at the bottom of tube, stop the stopwatch. Note the time taken for disintegration of the tablets and record the same in Batch Manufacturing Record.
If one or two tablets fail to disintegrate, the test is to be repeated using 12 tablet.
Disintegration Time of uncoated tablets= Not more than 15 minutes
Disintegration Time of coated tablets= Not more than 30 minutes
Tablets taken for testing and In-process control should not be added to the bulk batch to avoid mix-ups and cross-contamination.
Inspection, sorting of rejected tablets should be done as per SOP
The strips and cartons should be checked thoroughly for proper batch coding.
Manufacturing Chemist and Production Pharmacist should randomly check that the correct no. of strips are being packed in each cartons and also the number of 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 labelling and packaging, the coded cartons should be accounted for and rejected printed material should be destroyed in the presence of QC/QA Manager. Fill the destruction sheet and attach the same in the Batch Manufacturing Record.
It will be ensure that filling or packaging equipment has been properly cleaned after the completion of batch.
Filling or packaging of next product should not commence until the IPQA has given the ‘Line Clearance’.
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