Validation & Qualification (Cleaning, Equipment, Process, Methods)

In industries such as pharmaceuticals, biotechnology, and medical devices, ensuring the quality and safety of products is of paramount importance. Key roles in this regard are played by the concepts of validation and qualification, especially concerning cleaning processes, equipment, manufacturing processes, and analytical methods. These processes are crucial for ensuring compliance with regulatory requirements, minimizing risks, and ensuring the integrity of the end product.

What do Validation and Qualification mean?

Qualification and validation are crucial quality assurance tools for manufacturers of medical devices, which are used in addition to verification. While verification ensures that a product meets specified requirements, qualification and validation go further by demonstrating that facilities, equipment, and processes are suitable for their intended tasks and reliably fulfill them.

Qualification involves verifying facilities, equipment, and rooms to document their suitability for critical tasks. This is done through the following steps:

  • Design Qualification (DQ)
  • Installation Qualification (IQ)
  • Operational Qualification (OQ)
  • Performance Qualification (PQ)

Together, these steps ensure that the qualified object is correctly installed, functional, and capable of reliably performing intended tasks within defined limits.

On the other hand, validation refers to the documented evidence that a process, method, or product meets its intended purpose with the required reliability in practical use. In the field of medical devices, this includes process validation for production processes, method validation for non-standardized quality control procedures, and development validation of the medical device itself, including clinical evaluations and performance testing.

The Four Phases of Qualification in Detail

The qualification process in the pharmaceutical industry, which is based on EU GMP regulations, consists of four key phases: Design qualification (DQ), installation qualification (IQ), functional qualification (OQ) and performance qualification (PQ). This process is essential to demonstrate the suitability of systems for the intended purpose and to obtain a manufacturing authorization.

  • Design qualification (DQ) proves that the design of a system meets the defined requirements.
  • Installation qualification (IQ) confirms that the system has been correctly installed and documented.
  • Operational qualification (OQ) proves that the system functions under specified conditions.
  • Performance qualification (PQ) shows that the system works consistently and reliably under normal operating conditions.

The Importance in Different Areas

Cleaning Validation

In the pharmaceutical industry, where the manufacture of drugs, medical devices and medicines takes place, minimizing contamination and cross-contamination in cleanrooms is essential. Comprehensive cleaning and disinfection are required to ensure the safety of the product, personnel and the environment. Cleaning validation plays a key role in this by providing documented evidence that cleaning processes are effective and guarantee a safe product.

The cleaning processes must be effective in accordance with the regulations of the European Hygienic Engineering and Design Group (EHEDG) and the GMP guidelines and ensure consistent product quality. This includes carrying out risk analyses, defining residue limits and documenting the cleaning and disinfection processes.

Equipment Qualification

Equipment qualification is essential in the pharmaceutical industry as it not only relates to manufacturing, testing and sampling equipment, but is also a fundamental part of quality control. It aims to ensure, through inspection, testing and evaluation, that equipment is compliant and functions reliably to ensure the manufacture of high quality products consistently. Failure or misuse of equipment can lead to costly risks, time delays and loss of quality.

Process Validation

Process validation is the confirmation through objective evidence that a process consistently produces results that meet the specified requirements for a specific intended use or application.

Process validation follows a structured framework that typically includes three main phases:

  1. Installation Qualification (IQ): Verifies that the process equipment and systems are installed correctly according to manufacturer specifications. This includes checking that all parts are present, correctly installed and configured and that the installation complies with the predetermined requirements.
  2. Operational Qualification (OQ): Ensures that the equipment or process functions correctly under all intended operating conditions. This includes verification of equipment functions and operating processes under simulated conditions to confirm that the equipment consistently performs as expected.
  3. Performance Qualification (PQ): Confirms that the process consistently and reliably delivers the expected results under normal working conditions. This involves checking the performance of the overall process over a defined period of time, often including actual production conditions.

Method Validation

Method validation is the process of ensuring that an analytical method reliably and reproducibly delivers the desired results, regardless of the user or time. It confirms that the method is suitable for its intended use. Validation is necessary when new methods are introduced into routine analysis, when methods are changed or when methods are transferred. Essential validation parameters according to regulatory guidelines such as ICH Q2(R1) include accuracy, precision, specificity, limit of detection and quantification, linearity, working range and robustness. These criteria demonstrate the reliability of the method under different conditions. Method validation is essential for quality assurance in the pharmaceutical industry to ensure compliance with regulatory standards and to ensure the safety and efficacy of products.

Validation and Qualification as the basis for Safety & Quality

Validation and qualification are essential elements in the quality assurance system of any manufacturing industry serving regulated products. These processes are not only a regulatory requirement, but also a demonstration of a company’s commitment to the quality, safety and efficacy of its products.

 

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