Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Ministry of Health
Alexandre Padilha
Directors Deputies
José Agenor Álvares da Silva Neilton Araújo de Oliveira
Jaime César de Moura Oliveira Luciana Shimizu Takara
Chief of Staff
Vera Maria Borralho Bacelar
Writing
Anderson Vezali Montai
Revision
Jacqueline Condack Barcelos
Lúcia Sciortino Giorgis
Nelio Cezar de
Aquino Roberto dos
Reis
5
Since GMPs are dynamic and are continuously evolving, it is important that
pharmaceutical industries always seek improvements in water purification
processes, aiming to reduce contamination risks.
The main purpose when preparing this document is to describe the minimum
requirements needed for water production systems for pharmaceutical use, as
well as the pharmaceutical market update on Anvisa’s regulatory trends, with
regard to the following topics:
This document will cover only the criteria related to the production of
purified water and water for injections for pharmaceutical use. As a
reference, international guidelines, national legislation and the experience of
Anvisa on health inspections were used. Alternatively to the criteria
presented in this document, different procedures may be adopted, provided
they are technically justified.
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2. CONSTRUCTION MATERIALS OF
WATER PURIFICATION SYSTEMS
Materials that come into contact with the water for pharmaceutical use,
including pipe, valves and assemblies, seals, diaphragms and instruments,
should be selected to meet basic requirements, among which the following
may be mentioned:
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For the construction of the Water Systems for Pharmaceutical Use materials
must have appropriate sanitary specifications. Some materials considered
own sanitary elements to a water purification system are stainless steel 316L
(low carbon contents) and polyvinylidene fluoride (PVDF).
The reservoir used to store water should be suitable for its intended purpose,
i.e., it must be constructed with inert material so that it is not a source of
contamination of its contents. The construction material must have
appropriate characteristics and roughness to difficult waste adherence,
biofilm formation and corrosion by sanitizing agents. Electropolished 316L
stainless steel, with low roughness, is the most common choice to meet these
requirements.
Using 304 stainless steel is not recommended, since it does not have adequate
resistance. The 316L stainless steel, in turn, has molybdenum and low carbon
contents in its composition, which greatly increases its resistance against
corrosion, helping to reduce the risk of water contamination.
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3. PRODUCTION TECHNOLOGIES OF
PURIFIED WATER (PW)
The method chosen for purifying water, that is, the sequence of purification
steps, must be appropriate to the quality of produced water. The
specifications for the water purification equipment and storage and
distribution systems should have configurations that prevent microbial
proliferation.
There are different technologies that can be employed for the production of
PW. Usually PW is produced by deionizers, reverse osmosis, ultrafiltration
and/or electro-deionization. However, the most common is a combination of
these technologies.
When the company uses a barrier filter immediately before the storage tank,
there must exist a sampling point before this filter and a periodic sampling to
ensure that the water before the filter is not a source of microbiological
contamination.
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These processes are renewable, respectively, with acids and bases. This
process alone does not produce high purity water because the process releases
small fragments of resin, facilitates microbial growth and promotes low
removal of organic wastes.
Considering that deionizer beds are potential sources of microbial growth and
biofilm formation due to its working principle and the constitution of the
resins, according with current GMP concepts, the existence of systems where
terminal steps of purification consist of deionization followed by a barrier
filter is not appropriate.
The most used technique as the final treatment step in the production of PW
is reverse osmosis, because it is able to greatly reduce the risk of microbial
contamination of the water, besides being of easy operation and maintenance.
Ultrafiltration and distillation can also be used for this purpose.
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4. PRODUCTIO TECHNOLOGT Y OF
WATER FOR INJECTIONS (WFI)
The water coming from the public network supply can contain contaminants,
such as chlorides and volatile organic substances. Because these
contaminants have a physical size smaller than water, the semipermeable
membranes used in reverse osmosis are not able to retain them. Moreover,
currently there are no effective methods for the identification of all possible
toxic contaminants present in water.
11
A biofilm consists of a large variety of gram-positive and gram-negative
bacteria.
Pathogenic bacteria are frequently found in biofilms, particularly
mycobacteria.
Biofilms are very difficult to be eliminated. Any attempt to use biocides
results in a rapid increase in the growth of biofilms after treatment.
Biofilms may be formed on the permeate side of the membrane, among
others, by the following manners: when there are microscopic holes and
fissures in the membrane or when the permeate side of the membrane is
not sterile.
Biofilm will grow and become very resistant to sanitization due to
glycocalyx.
The reverse osmosis is a percentage removal system: due to the high
concentration of microorganisms, metabolic byproducts, exotoxins,
among others, can pass through the membrane.
Many types of reverse osmosis membranes do not support sanitization at
high temperatures.
In other words, the reverse osmosis membranes will become, in practice,
in a point of great microbial growth. Since bacteria in the biofilm grow
and metabolize several metabolic byproducts are secreted, which include
proteins and carbohydrates, some of which may be biologically active.
These contaminants are not easily identifiable and quantifiable.
Currently it is not possible to assume that the quality of the water for
injection prepared by reverse osmosis is as safe as the water prepared by
distillation. Technically the reverse osmosis technology is inferior to
distillation due to a higher risk of physical chemical, biological and
microbiological contamination of the water.
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Considering these factors, it is evident that the process of first choice for
obtaining WFI is distillation, in equipment whose internal walls are
manufactured of suitable metal, such as stainless steel AISI 316L, the neutral
glass or quartz. Alternatively, the WFI obtained by an equivalent or superior
process to distillation for removal of chemical contaminants and
microorganisms, since it is validated and monitored for parameters
established.
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5. DISTRIBUTION AND STORAGE OF
WATER FOR PHARMACEUTICAL USE
(PW AND WFI)
The capacity of the storage tank should be sufficient to provide short term
reserve in case of failures in the equipment of water treatment or production
incapacity because of sanitization or regeneration cycle. The distribution of
PW and WFI should be performed with continuous circulation ring, since a
water system without recirculation ring can be considered basically a “dead-
point”. The proliferation of contaminants inside the storage tank and in the
circulation ring must be controlled.
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Conditions with no flow or low flow can cause microbial proliferation and
development of biofilms, especially in pipelines for water distribution.
Considering the importance of the flow of water to control microbial load,
this parameter must be constantly monitored.
Moreover, for production and distribution of water for injection (WFI) the
absence of a storage and distribution system is unacceptable because of the
high risk involved in the process.
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In systems kept warm, temperature reduction, when required by the process,
should occur for the shortest time possible. The cooling cycle and its duration
must be considered during system qualification and must provide satisfactory
results. In hot systems water reservoirs should be jacketed to assist in
maintaining the water temperature.
Considering the current concepts of GMP and the mitigation of the risk
inherent to the process of production, storage and distribution of water for
pharmaceutical use, as well as the technical concepts involved in chemical
and thermal sanitization technologies, it is possible to infer that the thermal
sanitization of the system must be always the first choice. Thermal
sanitization is performed by sanitary heat exchangers installed in the system.
In this process there is no opening in the system, no need to shutdown the
system and also there is no need to perform washing with consequent
disposal of water to eliminate chemical agents required in the chemical
sanitization.
Considering the stringent quality requirements of water for injection and the
inherent risk in the production process, it is difficult to maintain a WFI
system operating properly at room temperature and performing only periodic
chemical sanitizations. Furthermore, systems maintained at room temperature
are susceptible to contamination, which is contrary to the principles of risk
management of current GMP.
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Storage and distribution WFI systems must primarily be maintained at
elevated temperatures for as long as possible, as well as undergo periodic
thermal sanitizations. When there is the need for using water at a lower
temperature, for process reasons, it is recommended that the time in which
water is maintained at low temperatures is the lowest possible, i.e., when
there is no demand for use of this water (for example, in periods during the
night or weekends) it must remain heated. Therefore, it is important the
correct design and installation of sanitary heat exchangers with capability to
quickly heat and cool the water.
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6. QUALIFICAFION OF PW AND WFI
SYSTEMS
All systems of water for pharmaceutical use are considered critical systems of
quality and of direct impact on the quality and safety of medicines, so they
must be qualified. The qualifications must follow procedures previously
written and approved. The data obtained must be duly recorded and reviewed
for approval. In the qualification process, possible seasonal variations that
may affect the quality of water for pharmaceutical use should be considered.
Sanitization or sterilization techniques employed should be considered during
planning the system design and its performance must be demonstrated during
qualification activities.
Phase 1 is the first step of the study and precedes the use of water by the
pharmaceutical industry. It should be performed whenever a system is
starting productive activities or when undergoes changes that impact the
process. The initial concept for Phase 1 is that there is an intensive
monitoring of all sampling points of the system for all parameters specified
for water, all consecutive days for at least two weeks. An important
observation to be made is that this phase is just used to verify that the system
is robust and has capability to reliably produce, store and distribute PW or
WFI.
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It is also during this phase that the company must adjust its key operational
procedures according to technology and reality of the respective system of
purification, storage and distribution. Therefore, in Phase 1 is not justifiable
to approve a qualification study that has out of specification results, or even
technical problems. In such a situation the company must open a deviation,
properly investigate the causes of the deviation, implement corrective actions,
and finally perform again the Phase 1.
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Generally it is expected that Phase 2 will also be completed without
significant deviations in the process of production, storage and distribution of
water. The approach should also:
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7. REVISION OF WATER SYSTEMS
(PW E WFI)
The systems and results obtained in the monitoring of water quality must be
reviewed at appropriate regular intervals. The review team should include
representatives from engineering, quality assurance, operations and
maintenance areas.
The main objectives of the periodic review of the water system are the trend
analysis of the data of quality control, deviations, corrective actions, out of
specification results, among others, just to conclude if there is any trend,
either positive or negative, when appropriate, to establish a change plan.
Examples of values that can be set right after a correct periodic review are the
specifications of alert limits.
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It is noteworthy that in the periodic review of monitoring data obtained with
the equipment installed in line and also the results of tests performed in the
laboratory should be considered.
The elaboration of a correct periodic review of the water system must provide
subsidies and technical evidence that the system is robust and operates
without negative trends to the process, or requires corrective actions. The
conclusion of the report should be clear about the need for corrective actions
and the need for a new requalification of the installation, operation or
performance (Phases 1, 2 and 3).
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8. FINAL CONSIDERATIONS
The technical guidelines in this document, extracted from technical rules and
national and international pharmacopoeias, seek to guide companies for
occasional needs of adequacy to the current law. These guidelines indicate
the need to seek continuous improvements in production systems of purified
water and water for injection. Meeting the current Good Manufacturing
Practices, companies reduce the risk to the quality of manufactured products.
Thus, they are contributing to the improvement of the quality, safety and
efficacy of medicines consumed by the population.
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9. LITERATURE REFERENCES
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EUROPEAN MEDICINES AGENCY. Reflection paper on water for
injection prepared by reverse osmosis. London, 2008.
(EMEA/CHMP/CVMP/ QWP/28271/2008). Disponível em:
<http://www.emea.europa.eu/docs/en_GB/document_library/Scientific_guide
line/2009/09/WC500003403.pdf>. Acesso em 27/12/2012.
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