Sartorius Weighing Seminars
Qualified Weighing in Pharmaceutical Labs
Regulations and Procedures to ensure best Weighing Accuracy in your Laboratory
Sartorius Weighing Seminars Qualified Weighing in Pharmaceutical - - PowerPoint PPT Presentation
Sartorius Weighing Seminars Qualified Weighing in Pharmaceutical Labs Regulations and Procedures to ensure best Weighing Accuracy in your Laboratory Qualified weighing, Avoid errors and understand their daily impact on your weighing
Regulations and Procedures to ensure best Weighing Accuracy in your Laboratory
conditions
problems
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equipment
standards – Calibration Weights
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−
stable temperature and humidity
−
better on the first floor than on upper floors
−
especially low frequencies
Air condition Open doors Open windows Sunlight Air draft
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especially low frequencies < 10Hz should be avoided
−
better to be closer to a wall, than in the middle of the room
temperature)
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draft unstable table Humidity Hustle and Bustle Vibrations
− avoid infrared radiation;
no direct light e.g.... a desk lamp
Air condition Open doors Open windows Sunlight Air draft
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draft unstable table Humidity Hustle and Bustle Vibrations
and container.
− This force is not constant. It’s influenced by humidity, the user and handling of
samples and containers.
− The weight readout drifts in one direction. Values are non-repeatable.
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− substances or containers with low electrical conductivity − large surfaces (plastic or glass containers, filters)
− internal friction in powders, external friction − transfer of electrical charges by persons − problem increases with decreasing humidity (<40%)
Internal solutions:
semi-micro, analytical and 1mg-balances External solutions
containers and membrane filters
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The problem: Magnetic materials in samples or containers, such as nickel, iron, steel, generate force fields that act against the permanent magnet of the weighing system.
position of the sample on the weighing pan. How to avoid:
nonmagnetic object to distance the sample from the weighing pan.
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One of the worst errors that occurs during weighing is caused when the balance is unlevel.
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α α α α
400µm
Example: If the balance is inclined only 400m (Thickness of a business card) on one side an incorrect measurement is produced:
displayed 0.37mg too low
allowable tolerance of a 200g ± 0.3mg E2 calibration weight for an analytical balance. Error calculation: md = m · cos α = 200g · cos (0,11° ) = 199,99963g
α = arctan (0.4mm/200mm)
∆m = -0.00037g
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α α α α
400µm
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Balances need to be warmed up (after new installation)
To avoid subsequent warm up periods :
mode
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Was passiert wann konkrete Empfehlungen
Hygroscopic substances:
Efflorescent substances
sample at different times
How to avoid?
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Bilder Tauschen
Sample containers are very often not sufficiently acclimatised:
weighing chamber and sample/sample vessels
− sample too cold: “weight increasing” − sample too warm: “weight decreasing”
How to avoid?
containers
inside weighing chamber before weighing
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temperature and causes “gain-weight” effects
recognised after 10 minutes
50 to 100g
hygroscopic
causes additional turbulence and temperature effects
and drifting
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How to avoid?
tweezers or some other suitable gripping device
a spatula which is long enough to keep the hand outside
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Bilder Tauschen
Ergonomic aspects:
sample into small vessels, flasks or tubes
but the sample is not inside the container How to avoid:
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USP Minimum Sample Weight Determination
12,6 Kg
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divided by 3!
USP 34 NF Chapter 41 Weights and Balances
weight
known – three times the standard known – three times the standard deviation out of min. 10 replicant weighings
exceed 0.1% of the minimum sample weight (M):
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001 . M U ≤
U M * 1000 ≤
SD U * 3 =
) 49 ( 001 . M U ≤
determination of the minimum sample weight on site
must be tared
is = 1000 digits
applicable for „assays“!!
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USP, Chapter 41
applicable
to measured on the balance
to measured on the balance
local FDA inspector...
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from a Sartorius USP Certificate
In pharmaceutical labs in Europe you will find 3 different minimum weights, that should not be mixed up.
Legal Metrology (only Europe)
− Min Weight specification with legal
Example, Semi-Microbalance min acc. EGLM = 1 mg min acc. ISO (1%)
min acc. USP approx. 20 mg
− Min Weight specification with legal
character – you must not fall below this weight
− on ISO 17025 based min weight, self
defined, acc internal accuracy demands.
− inspected by FDA – mutual character
in USA and for any manufacturer exporting to US
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min acc. USP approx. 20 mg
based on double standard deviation (K=2), USP is based on three times SD (K=3)
compared to the USP (e.g. Linearity, weight tolerances, tempeture drift, rounding error).
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decimal balance in “perfect” conditions
is significantly influenced by ambient conditions at the place of installation. Recommendation: Use a microbalance with a readability
absolute limit it is not recommended since performance is not guaranteed
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Readability/Balance Type 0.1g 1 g 1 g 10 g Minimum Sample Weight 1 mg 2 – 5 mg 5 – 15 mg 15 – 100 mg 10 g 0.1 mg 1 mg * typical = based on Sartorius experience 15 – 100 mg 100 mg 1 g
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practical use.
validated process
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process
DQ = Design Qualification IQ = Installation Qualification Technical specification for equipment (specification meet the user requirements) Equipment is delivered and installed in accordance with the Before Purchasing At
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IQ = Installation Qualification OQ = Operational Qualification PQ = Performance Qualification installed in accordance with the qualified design Test of operational functions Test of specified application Ongoing performance tests and preventive maintenance At installation After installation At regular intervals
based on the intended purpose of the instrument
− Functional specification
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− Functional specification − Technical / performance specification for equipment
− Specification meet the user requirements − Design is compliant with GMP and other regulatory requirements − Details all equipment that must be ordered
instrument is delivered as specified, is properly installed in the selected environment, and that this environment is suitable for the instrument
− Comparison of the equipment received with the purchase order
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− Comparison of the equipment received with the purchase order − Equipment check for any damage. − Documentation check for completeness − Installation of hardware − Initial cleaning − SQ-min-Identification
Good to know: Responsibility for IQ lies, as the whole EQ, with the user but activities can be supported and carried out by the vendor.
instrument will function according to its operational specification in the selected environment
− meets manufacturer or users specification
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− meets manufacturer or users specification − operating within established limits and tolerances
− Basic function check and check if the instrument powers up after it is switched on − Calibration − Operator training
instrument consistently performs under ‘full operational‘ conditions, and is appropriate for the intended use
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Good to know: PQ is described as a separate activity, for balances it is appropriate to perform it in conjunction with OQ
generic risk analysis
OQ planning and of protocols for the IQ and OQ tests
FDA guidelines
balances
integrated in existing QM systems
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One main question remains:
− Is it important to test the right colour of the equipment housing? − Is it important to test if the right power supply was delivered? − Is it important to issue a calibration certificate?
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− Is it important to issue a calibration certificate?
necessary)
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Focus on the critical instruments and critical points
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critical areas
management
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What does this mean?
− to focus on critical aspects
process should be commensurate with the level of risk
systems and processes
identification of potential risks and is a key integral component of quality risk management
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individual project risk, critical functions of equipment and systems and define the scope of equipment qualification
51:1999 and 73:2002, DIN EN ISO 14971:2000, the GMP Regulations of the FDA (Risk Based Approach) and in ICH (Q9 – Quality Risk Management)
relevant processes
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A risk of a potential failure can be evaluated by the probability of occurrence, the severity and the probability of detection. Risk Priority Number RPN = O x S x D (can vary from 1 to 125)
O = Probability of occurrence S = Severity D = Probability of detection
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D = Probability of detection O (occurrence rating): 1= Unlikely 2= Very low 3= Low 4= Moderate 5= Likely/High S (severity rating): 1= No impact 2= Insignificant 3= Moderate impact 4= High impact 5= Catastrophic impact D (detection rating): 1= High 2= Moderate 3= Low 4= Very low 5= Unlikely
O (occurrence rating): 1= Unlikely 2= Very low 3= Low S (severity rating): 1= No impact 2= Insignificant 3= Moderate impact 4= High impact D (detection rating): 1= High 2= Moderate 3= Low 4= Very low
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3= Low 4= Moderate 5= Likely/High 4= High impact 5= Catastrophic impact 4= Very low 5= Unlikely
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space program
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according to how serious their consequences are, how frequently they occur and how easily they can be detected
balances where evaluated with an FMEA .
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To evaluate possible risks you have to identify them
temperature inside a draft shield?
Once you know about the possible risks your are able to decide
Risk analysis Regulatory compliance Choice of best balance Processintegration Calibration weights Installation Maintenance
Advanced
Compliance
Page 1
User training Calibration interval Balance-Qualification (IQ/OQ) Warning - and action thresholds Calibration weights Installation Correct weighing
Risk Analysis Measureme nt process requirement s
Advanced
Pharma
Compliance
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Expert Input
Certificate These are the
you need!
Sartorius weighing specialist
We recommend.. .
Our weighing specialists will assist you by
This documentation (Risk Analysis) is an essentiell part of your
Advanced
Compliance
Two things are important in daily work with the balance in a pharma lab:
making sure that the balance always is working within the defined tolerance limits
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sample or sample container influences
Every Lab, which is accredited according to ISO/IEC 17025 or works according to the GLP/GMP guidelines must regularly calibrate its testing equipment, and adjust as necessary.
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But, when and how often should calibration/adjustment be carried out on regular basis?
The customer has to clarify “how critical is the weighing value in the complete process”
Simple rule:
calibration should be done before every series of measurement
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Better:
calibration results and defined warning and action thresholds
T ime Measuring Value
Upper intervention limit T arget Value Upper warning limit Lower intervention limit Lower warning limit
T ime Measuring Value
Upper intervention limit T arget Value Upper warning limit Lower intervention limit Lower warning limit
Increase Interval Increase Interval T ime Me a s uring V a lue
Upper intervention limit T arget V alue Upper warning limit Lower intervention limit L
T ime Me a s uring V a lue
Upper intervention limit T arget V alue Upper warning limit Lower intervention limit L
Decreas e Interval Decreas e Interval
case 1: increase intervals case 2: decrease intervals
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T ime Measuring V alue
Upper intervention limit T arget Value Upper warning limit Lower intervention limit Lower warning limit
T ime Measuring V alue
Upper intervention limit T arget Value Upper warning limit Lower intervention limit Lower warning limit
case 1: increase intervals case 3: call service case 2: decrease intervals
Often calibration is done only at one point
Better:
prominent points of the characteristic
ed Weighing V alue
Near maximum Working range
ed Weighing V alue
Near maximum Working range
prominent points of the characteristic balance curve
regulatory requirements of USP
is finally used; typically this is 10 to 20%
point the absolute error is the highest
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Dis played
Near minimum weight
1 2 3
Dis played
Near minimum weight
1 2 3
balances are designed for Pharmaceutical labs and include functions, which make monitoring easier for the user
isoCAL isoCAL
balance within an narrow tolerance band without testing efforts
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It corrects:
(temperature limits can be set)
(location, differences in altitude)
fluctuations (but it‘s not a compensation)
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Model Temperature changes by After a time interval of Ultra-micro, Micro, Semi-micro, Analytical 1mg-precision balances ≥1200g 1.5 ° C 4h 1mg-precision balances ≤1200g 10mg-precision balances ≥4200g 2° C 6h
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10mg-precision balances ≥4200g 10mg-precision balances ≤ 4200g 4° C 12h 100mg-precision balances 4° C 24h
The parameters can be changed by the user, but only in the direction to smaller values.
retraceable calibration weight. Best is, to test isoCAL at the same time that the balance is calibrated, given by the defined test interval.
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function, however it is possible to expand the test intervals.
One of the worst errors that occurs during weighing is caused when the balance is unleveled.
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α α α α
400µm
Example: If the balance is inclined only 400µm ( thickness of a businesscard) on one side an incorrect measurement is produced: md = m · cos α = 200g · cos (0,11°) = 199,99963g
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α α α α
400µm
md = m · cos α = 200g · cos (0,11°) = 199,99963g α = arctan (0.4mm/200mm) ∆m = -0.00037g That means, the mass of 200g is displayed 0.37mg too less The resulting error is greater than the allowable tolerance of a 200g ± 0.3mg E2 calibration weight for an analytical balance.
The automatic, motorized leveling featured
correctly leveled and performs the time consuming alignment of the balance. It is activated by pressing a start key or
It is activated by pressing a start key or fully automatically in conjunction with the isoCAL function
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For quick determination of the standard deviation to check the repeatability of results Definition
loaded several times with the same weight under constant ambient conditions.
the repeatability
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the repeatability
(based on 6 individual measurements).
changed.