PHARMACEUTICAL INSPECTION CONVENTION

PHARMACEUTICAL INSPECTION CO-OPERATION SCHEME

PI 028-2
1 January 2021

AIDE-MEMOIRE

GMP INSPECTION RELATED

TO PACKAGING

© PIC/S 2021
Reproduction prohibited for commercial purposes.
Reproduction for internal use is authorised,
provided that the source is acknowledged.

Editor: PIC/S Secretariat

e-mail: [email protected]
web site: http://www.picscheme.org

PI 028-2 Page 1 of 8 1 January 2021

 TABLE OF CONTENTS

Page
1. Document History ........................................................................................... 2
2. Introduction ..................................................................................................... 2
3. Purpose .......................................................................................................... 2
4. Scope ............................................................................................................. 3
5. Aide-Memoire ................................................................................................. 3
6. Revision History .............................................................................................. 8

1. DOCUMENT HISTORY

Adoption by Committee 31 October 2008

Entry into force 1 March 2009

2. INTRODUCTION

2.1. The process of packaging of medicinal products is listed among the risk factors
that may affect the quality of the finished medicinal products and may also cause
mix-ups.

2.2. The increased number of the defects of medicinal products occurred due to
deficiencies in the process of labelling and packaging has drawn inspectors’
attention towards the need for identifying and clarifying the critical aspects of this
specific stage of inspection, in order to have a uniform interpretation of the
provisions of the current GMP guide concerning packaging of medicinal products
and prevention of mix-up.

2.3. In the light of technological progress, considering the wide variety of medicinal
products developed, the 2005 PIC/S Seminar (Bucharest, Romania) was
dedicated to the GMP inspection of the final stage of manufacturing process
(primary and secondary packaging, labelling).

The first version of the Aide-Memoire is the outcome from the 2005 PIC/S Seminar
with the latest version providing updated cross-reference to the PIC/S GMP Guide
PE 009-14.

3. PURPOSE

3.1. The purpose of this document is to provide guidance for GMP inspectors in
preparation for inspections. This document aims to define the minimal
requirements acceptable for an inspector as well as the requirements that provide
maximum safety for the finished product (“best practices”).

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 3.2. The Aide-Memoire should enable the inspector to assess the GMP compliance of
the packaging process using the quality risk management tools.

4. SCOPE

4.1 The following Aide-Memoire describes different areas which could be evaluated
during the GMP inspection of packaging and labelling process. However, the Aide-
Memoire should be considered as a non-exhaustive list of areas to be looked at
during an inspection.

4.2 At the time of issue, this document reflected the current state of the art. It is not
intended to be a barrier to technical innovation or the pursuit of excellence. The
advice in this Aide-Memoire is not mandatory for industry. However, industry
should consider PIC/S recommendations and Aide-Memoires as appropriate.

5. AIDE MEMOIRE

1. Area of
Supporting
operation/ Notes Crucial questions
documents
Items
Packaging materials
1.1 Quality and  purchasing from approved  What is the policy for GMP Guide
purchasing suppliers; suppliers’ approval? Part I - 1.4 vi,
 auditing the manufacturing  Show me the audit 1.8viii, ix ,
sites of suppliers of primary report 5.45, 5.46, 4.2,
packaging materials for 4.14
sterile products (vials, rubber
stoppers, syringes, etc.) and
of printed materials;
 compliance with  Do the primary
specifications; materials Ph.Eur
 up-dating the documents specifications comply
(quality specifications), in with the
accordance with the Pharmacopoeial
marketing authorization and parameters and limits?
any subsequent variations;
 delivery from supplier made
such as to preserve the
quality (to prevent
contamination).
1.2 Receipt  quality documents:  Show me the records GMP Guide –
certificates of analysis; and SOPs which apply Part I 5.30,
 checking the conditions for when receiving 5.45, 5.33,
packages shipment and primary packaging 5.47, 5.48
handling; materials or printed 4.22, 4.23,
 integrity checks and materials 4.24
identification of each batch  Describe internal
of primary packaging labelling system

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1. Area of
Supporting
operation/ Notes Crucial questions
documents
Items
material or printed material
received;
 de-dusting and cleaning of
packages on the outside
(separate area).
1.3 Storage areas  adequate capacity, order  Show me the GMP Guide
and organization, location seasonal/annual Part I 3.1 –
plan available; trends and results of 3.4, 3.18 –
 the cleaning status, temperature and 3.23, 3.25, 5.5,
procedure and records; humidity monitoring 5.7, 5.31,
 physically separated areas 5.32
for “quarantine”, “approved”,
“rejected/recalled” materials
or a system that provides
similar safety;
 secured conditions
(physically separated areas,
controlled, authorised
access) for storage of
primary and secondary
printed materials (cartons,
labels, leaflets);
 storage of one batch per
pallet – when the number of
recipients allows -, without
mixing batches on the same
pallet ;
 storage conditions adequate
to each category of materials
(qualification of the
ventilation, air conditioning
unit, critical parameters
monitoring – temperature,
humidity);
 existence of an efficient  Show me the location
system to prevent entrance plan and records
of rodents, insects or other concerning these
animals; activities
 adequate control over
destruction of materials.
1.4 Quality control  sampling plan and  Show me the sampling GMP Guide
conditions, according to the plan and records for Part I –
material being sampled; primary packaging 3.40, 3.41,
 specific laboratory materials (including 5.59, 6.1, 6.6,
equipment for the testing of labels) 6.17
packaging materials;  Show me the
approved specification Annex 1: 125

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1. Area of
Supporting
operation/ Notes Crucial questions
documents
Items
 testing of packaging and current results Annex 8: 1, 5
materials/packages in from internal testing
accordance with the  Show me the
methodology approved in certificates issued by
the marketing authorization QC for one or more of
(functionality tests according these materials /
to the manufacturer packages used for
specification and tests primary packaging
according to current edition
of relevant pharmacopoeia);
 integrity testing for primary
packaging, differentiated for
each category of finished
products (when applicable);
 in-process controls with
relevance for the quality of
the primary packages used
(weight, filling level, blister
scan, leak test, verification of
the printing of labels, bar
code reader challenges);
 assessment of the integrity
for a sterile product
packaging.
1.5 Manufacturing  designed and built-up to  Show me the GMP Guide
premises minimise the risk of qualification (IQ, OQ, Part I: 3.7, 3.8
(packaging contamination and mix-up - PQ) of utilities used
area) enough space, logical inside the primary Annex 1: 18,
positioning of packaging packaging area 28 - 30, 31 -
equipment, separation of  Show me the results of 35
each and every primary and environmental
secondary packaging line monitoring (especially
(different cleanliness levels); for primary packaging
 qualification (IQ, OQ, PQ) of of sterile products)
utilities (HVAC, PW, WFI,  How is the access
sterile steam, inert gases ensured for products/
used, if applicable); materials and
 monitoring of environmental personnel to
conditions based upon the production areas?
nature of the product (sterile
or non-sterile).
1.6 Packaging  high performance, qualified  Show me the SOP and GMP Guide
equipment and and well-maintained; records of the line Part I: 3.34–
process equipment, able to ensure clearance 3.39, 5.49 –
the control during the  Show me the checklist 5.59, 5.62
primary/secondary used for line clearance
packaging; Annex 15

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1. Area of
Supporting
operation/ Notes Crucial questions
documents
Items
 line clearance (working area,  IQ, OQ, PQ and CQ
packaging lines, label
printing machines and other
equipments should be clean
and free from any other
products, materials or
documents previously used);
 content of adequate level of
details on the checklist for
line clearance;
 line cleaning;
 cleaning of dust extractors  Show me the
 checking of the type of label qualification/validation
used and its attachment on of the packaging
the primary package; equipment/process
 the presence of safety  Show me the
elements of the package (to calibration and
prevent the counterfeit); maintenance records
 validation of the packaging for the packaging line
process (critical process  Show me the SOP and
operation) – protocol, report program for mix-up
and records; prevention
 adequate functioning of
electronic devices to
establish identity, such as
barcode or RFID readers.
 waste handling
1.7 Documents  batch packaging records  How do you ensure GMP Guide
(BPR) – on paper or the security of the data Part I: 4.8,
electronic form (attention entry in the electronic 4.9, 4.19,
paid to level of access, BPR? 4.21, 5.61,
electronic signature, etc.) for  Show me the records 5.15, 5.44
every batch or sub-batch of investigation of any
manufactured; discrepancies noticed
 SOPs and instructions for during reconciliation?
reconciliation, especially for  How did you
the printed materials investigate the
(including investigation of packaging process
any discrepancy noticed and deviations?
solving before batch  Show me the SOP for
release); handling the obsolete
 defined and adequate action or damaged printed
limits regarding packages
reconciliation;
 adequate control of return in
storage area of excess
packaging materials;

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1. Area of
Supporting
operation/ Notes Crucial questions
documents
Items
 adequate and documented
investigation of packaging
process deviations.
1.8 Personnel  adequate in terms of  Show me the records GMP Guide
qualification and training of medical checks for Part I: 2.1, 2.7
regarding hygiene practices, operators working in vi, 2.8 vii, 2.9
clothing and operation on primary iii and v, 2.10-
particular packaging packaging area. 2.12
equipments;  Observe and discuss
 knows and applies the with personnel
procedures regarding the involved in the
activity performed; packaging process, to
 performs operation reliably see the level of their
and with no impact on the knowledge on the
quality of the product; operations they
 training of maintenance perform
personnel and contractors.  Show me the records
of training on line
clearance SOP
1.9 Quality  Quality policy, risk  Show me the self GMP Guide
assurance management, risk inspection plan and Part I: 9.1,
assessment outcome 8.10, 8.12,
 self inspection system  How did you
(frequency based on the investigate the Annex 15: 11.1
critical aspects of packaging complaints related to – 11.7
materials/ processes, taking packaging?
into account the number and
gravity of the quality defects
and taking the appropriate
preventive and corrective
measures);
 investigation of complaints to
identify the package/
packaging related cause;
 assessment of the change
control impact on the
package/packaging of the
finished product, during the
whole shelf life of the
product;
 release procedure on printed
and primary packaging
materials;
 release procedure of printed
and primary packaging
materials

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 6. REVISION HISTORY

Date Version number Reasons for revision

1 January 2021 PI 028-2 Minor edits to update cross-references to PIC/S GMP

Guide (PE 009-14)

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