MFR of Azithromycin 250 Tablets IP

MFR of Azithromycin 250 Tablets IP

TABLE OF CONTENTS 

S.NO.	TITLE		Page No.
1.0	PRODUCT DETAILS
2.0	MANUFACTURING FORMULA
3.0	LIST OF EQUIPMENTS
4.0	GENERAL PRECAUTIONS
5.0	MANUFACTURING INSTRUCTIONS
6.0	MANUFACTURING PROCESS DETAILS
	6.1	GRANULATION
	6.2	COMPRESSION
	6.3	COATING
	6.4	BRAND DETAILS

 1.0 PRODUCT DETAILS:

Product Name	Azithromycin Tablets IP
Product Description	White color round shape, biconvex, film coated tablets  having both side plain
Strength	250 mg
Label claim	Each film coated tablet contains: Azithromycin (As Dihydrate) equivalent to Azithromycin Anhydrous – 250 mg
Batch Size	2,00,000 Tablets
Average Weight	354 mg
Shelf Life	24 months
Storage	Store in a cool, dry and dark place below 250C
Drug Category	Macrolide Antibiotics

2.0 MANUFACTURING FORMULA:

Material Name	Grade	Category	Quantity per Unit (In mg)	Overages	Batch Qty.  (In kg)
Dry Mixing
Azithromycin	IP	API	250 mg	5 %	52.500 kg
MCCP Plain	IP	Diluent	25 mg	—	5.000 kg
Binder
PVPK-30	IP	Binder	2.0 mg	—	0.400 kg
Sodium  Benzoate	IP	Preservative	0.7 mg	—	0.140 kg
Sodium Starch Glycolate	IP	Binder	10 mg	—	2.000 kg
Purified Water	IP	Diluent	0.13 ml	—	26.000 liter
Lubricant
Talcum	IP	Anti-caking agent	7.0 mg	—	1.400 kg
MCCP PH-102	IP	Diluent	25 mg	—	5.000 kg
Cross Carmillose Sodium	IP	Disintegrant	7.0 mg	—	1.400 kg
Crospovidone XL	IP	Disintegrant	3.5 mg	—	0.700 kg
Aerosil	IP	Glidant	1.5 mg	—	0.300 kg
Calcium Stearate	IP	Anti-Adherent	3.5 mg	—	0.700 kg

3.0 LIST OF EQUIPMENTS:                         

Sr.No.	Machineries/Equipments	Capacity	Equipment ID.
1.	Weighing Balance	100 kg
2.	Vibro Sifter	30 inch dia
3.	Paste Kettle with stirrer	100 liter
4.	Portable Stirrer	—
5.	Rapid Mixer Granulator (RMG)	160 liter
6.	Fluid Bed Dryer (FBD)	120 kg
7.	Multi Mill (screen size 2 mm and 8 mm)	—
8.	Double cone Blender	400 liter
9.	Halogen Moisture Balance	—
10.	Compression Machine	27 Station
11.	SS Containers	10 liter	—

4.0 GENERAL PRECAUTIONS:

• API Description: 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 sifting and after sifting).
• Set the Vibro Sifter (capacity: 30 inch dia) and sieve the Dispensed Materials as per Sieve Sizes mentioned below:

Material Name	Std. Qty. (kg)	Sieve No.
Dry Mixing
Azithromycin IP	52.500 kg	18 #
MCCP Plain IP	5.000  kg	60 #
Binder
PVPK-30 IP	0.400 kg	20
Sodium Benzoate IP	0.140 kg	20
Sodium Starch Glycolate IP	2.000 kg	60 #
Lubricant
Talcum IP	1.400 kg	60 #
MCCP PH-102  IP	5.000  kg	40 #
Cross Carmillose Sodium IP	1.400  kg	60 #
Crospovidone XL	0.700  kg	60 #
Aerosil IP	0.300  kg	14 #
Calcium Stearate IP	0.700 kg	60   #

• 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 Carmillose 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 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 (5.000 liter, 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: 160 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 (To be validated in next batch).

STEP –IV (BINDING OF DRY MIX MATERIAL):

Slowly add the binder of Step-II in dry mix materials of Step -III in Rapid Mixer Granulator running at slow speed impeller (1.02 ampere) for 5 minutes till binder addition. After binder addition run impeller and chopper both at slow speed (0.63 ampere) for 08 min 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: 15 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 1.0 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: 60°C. (To be validated in next batch)

Outlet Temperature: To be established.

Raking Frequency: After 30 minutes.

Drying Time: 02 Hours. (To be validated in next batch).

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 Double Cone Blender (capacity: 400 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:

Test	Specification
Appearance of  blend Blend Uniformity Blend Assay LOD	White color free flowing granular powder 90 % to 110 % 98 % to 103 % 1.0 % to 1.5 %

STEP – XI:

• Take Tare Weight of two Poly-lined HDPE Containers (capacity: 45 liter each), record the Tare Weight in BMR and unload the above blended material from Double Cone Blender in 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: 69.400 kg (100 %)

Actual Batch Yield Limit NLT 68.706 kg (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 27 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.	Parameters	Standard	No. of Tablets	In-Process  Frequency
1.	Feed frame alignment and adjustment	Should be satisfactory	—–	—–
2.	Lower Weight Assembly	Should be satisfactory	—–	—–
3.	Hydraulic Pressure	6-8 Tones	—–	—–
4.	Machine Speed	18 RPM -20 RPM	—–	—–
5.	Common Name of Die	Azithro
6.	Upper Punch Size	11 mm	­—–	—–
7.	Lower Punch Size	11 mm	—–	—–
8.	Avg.- Diameter	11 mm	6/Individual	2 hours
9.	Thickness of Tablets	3.70 mm ±.2 mm	6/Individual	2 hours
10.	Weight of 20 Tablets	6.940 gm. ± 3%	20/Composite	30 minutes
11.	Tablets for Dissolution	347 mg ± 2%	20/Composite	Before starting    the Compression —–
12.	Dissolution	NLT 80 %	—-	—-
13.	Product Description	White color round biconvex, uncoated tablets having both side plain	20/Composite	30 minutes
14.	Uniformity of Weight	347 mg ±5 %	20/Composite	01 hour
15.	Standard Average Weight of Tablets	347 mg ± 2 %	20/Individual	30 minutes
16.	Hardness	NLT 3 kg/cm2	6/Individual	30 minutes
17.	Disintegration Time	NMT 15 min	6/Composite	01 hour
18.	Friability	NMT 1%	20/Composite	01 hour

• Collect the compressed tablets in 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 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: 69.400 kg (100 %)

Actual Batch Yield Limit NLT 68.706 kg (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. No	Material Name	Batch Quantity
1.	Instacoat White Aq.III	1.388 kg.
2.	Purified Water IP	8.330 liter

STEP-II (LIST OF EQUIPMENTS FOR COATING):

Sr. No.	Machineries/Equipments	Capacity	Equipment ID.
1.	Coating  Machine and Coating Pan	42″
2.	Spray Gun	02	—
3.	Filter Cloth 100 #	0.5 mm	—
4.	Portable Stirrer	—	—

STEP – III (PREPARATION OF COATING SOLUTION):

• Take Purified Water IP (8.330 liter, at room temperature) in SS Container (capacity: 15 liter) and add Instacoat White Aq.III (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 proceed with coating process.

STEP – IV (COATING PROCEDURE):

• Coating will be done in one lot, take total compressed tablets for coating (69.540 kg).
• Load the tablets in coating pan (Capacity: 42″), start the hot air blower, set the inlet air temperature at 60°C to 65°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.

Parameter	Specification
No. of Baffles in coating pan	06
No. of Guns	02
Inlet Temperature	60°C to 65°C (To be validated in next batch)
Peristaltic Pump Speed	2- 4 RPM (To be validated in next batch)
Atomization	2.5 to 3.0 kg/cm2
Gun to Tablet Bed Distance	8 inch
BED Temperature	400C to 45 0C (To be validated in next batch)
Pan RPM	13 to 15 RPM
% Weight Gain	1.5 to 2.0 %
Coating Time	2 Hours

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

• After completion of coating perform the In Process checks as per below parameters:

Sr.No.	Parameters	Standard	No. of Tablets	In-Process Frequency
1	Product Description	White color, round  biconvex, film coated tablet having both side plain	20 No.	After batch completion
2	Weight of 20 Tablets after coating	7.080 gm. ± 2 %	20 No.
3	Average Weight after coating	354 ± 2%	20 No.
4	Individual Tablets Weight Variation	NMT 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.
5	Thickness	3.71 mm ± 0.2 mm	6 No.
6	Disintegration	NMT 30 min.	6 No.

STEP – VI:

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

 STEP – VII:

• Take Tare Weight of two Poly-lined HDPE Containers (capacity: 45 liter each), record the Tare Weight in BMR and transfer the coated tablets in 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: 69.400 kg (100 %)

Actual Batch Yield Limit NLT 68.706 kg (NLT 99 %) (To be established in next batch).