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TheStudy

The Studyofofthe
theDesign
Design
ofofProduction
ProductionSystems
Systems
ofofPurified
Purified Water for
thePharmaceutical
the Pharmaceutical Industry
Industry
By I. Lerin Riera,
R. Salazar Macian,
J.M. Suñé Negre,
and J.R. Ticó Grau
University of Barcelona
O
Part I on the design (description of func-
c tioning) is carried out for each of

W
ater used in the phar- them, together with a report on the
maceutical industry, design.
especially water used to
manufacture drug products (puri- General Considerations
fied water and water-for-injection)
is vital to the manufacture of these The chosen pharmaceutical plants
products and, therefore, should be have been labeled Pharmaceutical
considered as a raw material that Plant A, Pharmaceutical Plant B, and
needs to comply, at a minimum, Pharmaceutical Plant C.
with specifications set out in Pharm- The study for each of the three
acopeia. plants has been separated into two
Presently, validation is essen- d distinct sections:
tial to ensure the reliability of any
system to produce water of phar- 1. Study of the design: A descrip-
maceutical quality. The first step to ensure the cor- tion of the functioning of the system. To examine the
rect functioning of the system is that each instru- design of each production system of Purified Water,
ment, each component, all the building materials, the study has been divided into two phases:
and all other considerations in the design of these
systems should comply with ruling Pharmacopeias ‚ Production and storage of purified water
and the current Good Manufacturing Practice ƒ Distribution of purified water to points of use
(cGMP).
This study examines the design of the production 2. Report on design: Contains recommendations
systems of purified water for the pharmaceutical for each point of improvement* (both critical and
industry in three pharmaceutical plants where a study noncritical) detected by the study in the design.

130 Special Edition: Utilities Qualification


Pharmaceutical Plant A mental stages, a first stage of purification by means
of reverse osmosis and a second stage of polishing
In Figure 1, the fundamental stages to carry out a by means of ionic exchange resins.
systematic follow up on the flow of the water have • The dechlorination of the water prior to the
been numbered, from the moment it enters the sys- reverse osmosis step is carried out through the action
tem as feed water to the moment the purified water of a carbon filter.
enters the distribution loop where the different • Note that in the system there are two recircula-
points of use are found. tions: R1 and R2. These recirculations prevent the
water from remaining stagnant in critical equipment,
Study of the Design such as reverse osmosis membranes and the ionic
Description of the functioning of the system exchange resins, during periods when production is
stopped.
Production of Purified Water
Chlorination – flocculation – filtration – R1: The R1 water recirculation refers to the
decalcification – adding sodium hypochlorite – recirculation from the exit of reverse osmosis to the
carbon filter – 2 µm filtration – reverse osmosis – intermediate storage tank. This recirculation is put
Osmotic water storage tank – ionic exchange – 2 into operation if the osmotic water tank is full,
µm filtration – UV lamp – 0.22 µm filtration – which occurs when there is no consumption of
Purified Water storage tank. purified water, i.e., during the night, at weekends,
and holiday periods. At the same time, this recircu-
• Water purification is carried out in two funda- lation is also put into operation in case the conduc-

Figure 1
Production System for Purified Water Design Diagram:
Pharmaceutical Plant A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Glossary R1 R2 R3
1. Chlorination 9. Ionic exchange
storage tank resins
2. Sand filter 10. UV lamp 16
3. Decalcification 11. 2 micrometer
equipment and 0,22
4. Intermediate micrometer filters
storage tank 12. Purified storage
(adding of sodi- tank R1: Recirculation 1
um hipochloride) 13. UV lamp
5. Carbon filter 14. 0,22 micrometer R2: Recirculation 2
6. Intermediate filters R3: Recirculation 3 (Distribution loop)
storage tank 15. Heat exchanger
7. Reverse 16. Distribution ring
Osmosis to points of use
8. Osmotic water
storage tanks

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tivity values of the water when leaving the reverse system of bisulfite dosifications together with the
osmosis are higher than those of the established corresponding controls. It is advisable in the actual
limit. situation to:
R2: R2 water recirculation refers to the access to
the purified water tank to the osmotic water storage a) Strictly control cleaning and sanitization
tank. This recirculation is put into operation when procedures, which should occur at least once
the purified water tank is full, which occurs when a week in the beginning, then using experi-
there is no consumption of purified water. ence to indicate the necessary frequency to
ensure that microbiological levels are within
• With the aim to avoid excessive loss of water limits.
due to the rejection of the reverse osmosis, this goes b) Control water leaving the carbon filter twice a
into operation cyclically for 15 minutes every 120 week to establish the microbiological level.
minutes, recirculating through the R1 recirculation
to the storage tank. 2. Stainless steel tanks: These cannot be sterilized
with clean steam, so it is recommended that they be
Storage and Distribution of Purified Water to replaced with storage tanks that can be. Considering
Points of Use the possibility of the intermediate tank, an alterna-
Purified Water storage tank – UV lamp – 0.22 tive solution is to install a UV lamp at the entrance
µm filtration – heat exchanger – distribution loop to the reverse osmosis. This would achieve a much
– Purified Water storage tank lower microbiological contamination and provide
greater safety for the system.
The microbiological quality of both the purified
water from the storage tank and that of the water 3. Return of the distribution loop to the purified
flowing through the distribution loop is assured by water storage tank: Installing a UV lamp will avoid
the UV lamp and the two high efficiency filters of accidental contamination which might arise at any
0.22 µm installed in parallel before the water enters points of use. In this way, the correct microbiologi-
into the distribution loop where, except during holi- cal quality of the water entering the purified water
day periods, the water is constantly recirculating. tank coming from the return of the distribution loop
After any holiday period, sterilization with clean could be ensured.
steam is carried out at 121ºC for one hour. In addi-
tion, the loop is cleaned for sanitary purposes every 4. The 0.22 µm filters: Can be eliminated,
15 days with purified water heated to 80 – 85ºC for which would represent an economy, as the UV
90 minutes. lamps are considered to be enough to assure
microbiological quality. Keep in mind that
Report on the Design of Plant “A” although applying the high efficiency filters is a
Conclusions technologically correct option to ensure microbio-
logical quality of the water in the last stages, these
Having studied the detailed description of the filters represent a high-maintenance cost (steriliz-
functioning of the system, some points of improve- ing and regular changing). The use of ultraviolet
ment are proposed, and a series of recommendations technology along the pretreatment phase and at
for each are set down. distribution is considered an adequate technology,
as it maintains the microbiological quality level at
Recommendations lower maintenance costs.
1. Carbon filter: Although carbon filters are a
technological option for water dechlorination, they Pharmaceutical Plant B
invite a high risk of microbiological contamination
in the system. It is then advisable to eliminate such The study carried out is similar to that for Plant
filters and obtain dechlorinated water by means of a A. See Figure 2.

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Figure 2
Production System for Purified Water Design Diagram:
Pharmaceutical Plant B
1 2 3 4 5 6 7 8 9 10 11 12
R1

R2

Glossary
1. Chlorination storage 7. Reverse Osmosis
13
tank 8. Osmotic water
2. Adding of flocculant storage tanks
3. Dechlorination by 9. Ionic exchange resins R1
means of sodium 10. 1 and 0.22 micrometer
bisulfate filters
4. 10 micrometer filter 11. Heat exchanger R1: Recirculation 1
5. Adding of chelating 12. Purified storage tank R2: Recirculation 2 (Distribution loops)
agent 13. Distribution loop to
6. 5 micrometer filter points of use

Study of the Design: the two installations for demineralizing. In this way,
Description of the functioning of the system possible microbiological contamination in the inner
layers of resin is diminished when the equipment does
Production of Purified Water not produce water, whether there is no need for con-
Sand filter – decalcification equipment – chlo- sumption or simply because it is in reserve.
rination – Flocculation – adding of bisulfite – 10 • The microbiological quality of the water that
µm filtration – adding of abductor – 5 µm filtra - goes into the purified water tank and comes from the
tion – reverse osmosis – intermediate storage ionic exchange resins is ensured first by a 0.22 µm
tanks – ionic exchange resins – 1 µm filtration – filter and later by the heat exchanger. The water is
0.22 µm filtration – Heat exchanger – Purified stored at 80ºC in the heat-resistant storage tank,
Water storage tank. which is made of AISI 316 L stainless steel.

• As in Plant A, purification of water is carried in Storage and Distribution of Purified Water to


two stages, first, by a reverse osmosis unit and sec- Points of Use
ond, refining by means of ionic exchange mixed bed Purified Water storage tank – distribution loop
resins. – Purified Water storage tank
• Water dechlorination prior to reverse osmosis is
carried out by adding sodium bisulfite. At the same • It should be noted that the microbiological quality
time, note the addition of the chelating agent, which of both the water in the purified water tank and that of
avoids the precipitation of carbonates and calcium the water flowing through the distribution loop in this
sulphate on the membranes of reverse osmosis due plant is assured by increasing the temperature of the
to a possible excess of sodium bisulfate. water carried out by the heat exchanger to 80ºC.
• There is a double recirculation, R1, which Starting from the stainless steel storage tank the water is
includes the two storage tanks of osmotic water and pumped to the entire plant, flowing at 80ºC in a closed

Special Edition: Utilities Qualification 133


loop so as to ensure that the water is sterile in practice. such a way that any possibility of microbiological
To maintain the temperature, the storage tank for the contamination of the water entering the osmosis
purified water and the distribution loop are insulated. module is avoided.

As the flow of water is thermostatically con- 2. Regarding the R1 recirculation: Recirculation


trolled at 80ºC through the loop, no stoppages in the of water through the reverse osmosis module during
recirculation of the distribution loop are forecasted periods when production is stopped is not contem-
for its sanitization as supported by the microbiolog- plated. This implies the risk that the membranes in
ical data of this plant. In practice, the distribution such modules could be microbiologically contami-
loop is sterilized by means of clean steam at 121ºC nated. Install two UV lamps-one at the entrance of
for an hour after holiday periods. the reverse osmosis modules and one at the exit-to
ensure the microbiological quality of the water
Report on the Design of Plant “B” entering and leaving.
Conclusions
3. Section of the pipe in which water could remain
Having carried out and studied the detailed stagnant while the R1 is functioning: If the R1 recir-
description of the system according to the design culation is started up, there is a section of pipe
diagrams, the design can be considered to be correct. between the beginning of said recirculation (after the
In this design, the microbiological quality of the ionic exchange resins module) and the purified water
water in the distribution loop and the purified water storage tank where water could remain stagnant. One
storage tank is assured by heating the water to 80ºC, possible solution calls for not starting the water recir-
in contrast to the design of Plant A, where quality culation exactly as it has been designed (immediately
was ensured by the combined use of sterilizing fil- after the exit of the ionic exchange resins module),
ters and ultraviolet technology. but at the point where the water enters the purified
Keep in mind that the FDA(Guideline 1993) con- water tank. In this way, the dead leg can be avoided.
siders that heat, as an assurance of microbiological
quality in the distribution loop, can turn out to be 4. 0.22 micrometer filter at the entrance to the
more expensive than other systems. At the same purified water storage tank: Its elimination is recom-
time, it states that maintenance and control costs, mended. Despite being an option to ensure the final
together with the potential problems that other sys- microbiological quality of the water coming into the
tems might incur, could be higher than the cost of tank of purified water, the thermostatic control of the
power saved. water by means of the heat exchanger is considered
Some points that could be improved upon have to be sufficient assurance. It should be kept in mind
been detected. A series of recommendations are set that the water at the entrance to the purified water
out for each of them. storage tank must comply with the microbiological
limits of Pharmacopoeia.
Recommendations
1. Dechlorination by means of bisulfite: Pharmaceutical Plant C (Figure 3)
Dechlorination using bisulfite after the flocculation
and prior to the entry of the water into the modules Study of the Design:
of reverse osmosis could entail a risk of microbio- Description of the functioning of the system
logical contamination by use, as it is considered that
the dechlorination is carried out at a stage exces- Production of Purified Water
sively distant from the reverse osmosis. It is advis- Flocculation – chlorination – filtration – carbon
able for the chlorination to be carried out prior to the filters – 5 µm filtration – decalcification – ozona-
entry of the water into the reverse osmosis or, other- tion – 5 µm and 1 µm filtration – UV lamp – 1ST
wise, for a UV lamp to be installed at the point reverse osmosis – UV lamp – 2ND reverse osmo-
where the water enters into the osmosis module in sis – ozonation – Purified Water storage tank.

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Figure 3
Production System for Purified Water Design Diagram:
Pharmaceutical Plant C
1 2 3 4 5 6 7 8 9 11.a 10 11.b 12 14.a
7
R1

7 13

7 R1
Glossary
1. Adding of flocculant 11.a.Reverse Osmosis 14.b
2. Adding of chloride 11.b.Double reverse osmosis
3. Silex – anthracite filter 12. Purified water storage
4. Carbon filters tank R1: Recirculation 1: Distribution loops
5. 5 micrometer filter 13. UV lamps
6. Decalcification equipment 14.a.Distribution loop 1:
7. Ozonation Production
8. 5 and 1 micrometer filters 14.b.Distribution loop 2:
9. UV lamp Laboratory
10. UV lamp

• In this plant, water is also purified in two leave residual compounds, add odor or flavor, nor
stages, but differently from the other plants and, does it attack the membranes in the ionic exchange
because of the low conductivity of feed water, it is nor those in the osmosis stage. In this sense there
carried out through double reverse osmosis. should be no concern regarding the elimination of
• Dechlorination of the water is carried out using ozone after treating the water. However, it does have
two carbon filters in a parallel installation. a drawback when compared to chloride: Its effect is
• Note that from the moment the decalcified not as lasting, which implies that the water should be
water is obtained, its microbiological quality is treated later with chloride at a smaller dose (as a
ensured by the combined treatment of ozone (bacte- result of the prior treatment with ozone) or, as in this
ricidal and oxidizing agent) and of ultraviolet tech- case, repeat treatment along the entire system to en-
nology. sure the bacteriological quality of water thus treated.
• Throughout the system, the water is ozonated Nevertheless, it is well known that UV wavelengths
several times, specifically at the entry points to the employed in water treatment are 254 nm and 185
purified water storage tank, at the entry point com- nm; 254 nm UV light is employed in disinfection
ing from the production plant, and in all the returns and ozone destruction applications.
in the two distribution loops. Water is also ozonated
when it leaves the tank of purified water before the Storage and Distribution of Purified Water to
water enters each of the two loops, just prior to the Points of Use
last treatment with ultraviolet lamps. Purified Water storage tank – ozonation – UV
lamp – distribution loop – ozonation – Purified
Keep in mind that the use of ozone as a bacterici- Water storage tank
dal agent is far more convenient than treatment with
chloride; the effect of the ozone is not influenced by The design shows two independent distribution
the pH in the medium. On the other hand, it does not loops from a sole tank of purified water. The micro-

Special Edition: Utilities Qualification 135


biological quality of the water in the purified water tank and the modules of reverse osmosis: There is no
storage tank and the water flowing through each of recirculation of water between the purified water tank
the two loops is ensured by the joint action of ozona- and the modules of reverse osmosis in case of stoppage,
tion and UV lamps. At the same time, in each of the whether caused by the tank of purified water being full
returns of the two loops and before the water enters or by stoppages at weekends or holiday periods. In both
the tank of purified water, the water is again ozonat- cases, the water will remain stagnant in the pipes and
ed. A flow of ozone also goes to the tank for its ster- equipment from the entry of feed water to the modules
ilization. After holiday periods, sterilization of the of reverse osmosis (inclusive), with all the dangers of
two distribution loops is carried out by means of microbiological contamination that this entails.
clean steam at 121ºC for one hour. A system for water recirculation should be placed
between the tank of purified water and the two mod-
Report on the Design of Plant “C” ules of reverse osmosis, like the one in Pharmaceutical
Conclusion Plant A.

After studying the design of Pharmaceutical Plant 2. Carbon filters: To avoid the problems of micro-
C, it can be said that it is correct to achieve water of biological contamination and maintenance these
microbiological and chemical quality as set out in systems require, it is preferable to remove them and
the norms for purified water to be used in the phar- obtain dechlorinated water by means of a system of
maceutical industry. bisulfite dosage with its corresponding controls. It is
Note that there are two differences between the advisable to:
design of the Pharmaceutical Plant C and that of the
Pharmaceutical Plants A and B. a) Strictly record the cleaning and sanitization
The first difference is that once the water has been processes, which should be carried out at least
decalcified, ozone is used together with ultraviolet once a week. Experience will suggest the most
technology to assure microbiological quality. The other adequate frequency to ensure that the microbi-
difference lies in the double-sequenced reverse osmo- ological levels are within limits.
sis treatment, which enables correct conductivity of the b) Check the microbiological level of the water
water. The high quality level of the water obtained by twice a week at the point it leaves the carbon
double osmosis makes the ionic exchange resins in the filter.
system unnecessary, thus avoiding the drawbacks they
represent in the regeneration of same. 3. Ozonation: Bear in mind that, in this plant, the
Keep in mind that the application of double- ozone and UV treatments are used consecutively.
reverse osmosis is recommended only for water with Although apparently this is contradictory to previ-
low conductivity (under 600 (s/cm), as an increase ous statements; as a general rule, a UV dosage of
of concentration will overcome the retention capac- 90,000 (W-s/cm2 is required to completely destroy 1
ity of the reverse-osmosis, thus causing the water ppm (1 mg/l) of residual ozone.
leaving the osmosis modules to have a conductivity The bactericidal treatment of water by using
over the limits. ozone is a technologically correct option, but it is far
Should the water have a high conductivity too expensive. Therefore, it is recommended to
(600–1500 (s/cm), employ ionic exchange resins or replace this treatment with one less expensive, such
electrodeionization equipment (CDI), as these meth- as ultraviolet lamps, as these represent much lower
ods have a greater power of retention than that of maintenance costs.
reverse osmosis. Points of improvement are understood to be those
There are several points where improvements can points where the final quality of the product as well
be made. as the productivity of the process might be affected.
These points of improvement are divided into criti-
Recommendations cal and noncritical points.
1. Recirculation between the purified water storage Critical points are those which affect or might

136 Special Edition: Utilities Qualification


affect the quality of the fin al product and the opti - USP 23 relate those chemical and microbi ological
mi zation of which ensure the fin al qu ali ty and con- characteristi cs that water must possess to be within
sequently all ow fo r greater producti vity. purifi ed water specifications. Figure 4 co mpares the
Noncritica l points are those which do not affect specificati ons of the European Pharmacopoeia with
the fin al quali ty but the optimization of which those of the USP 23.
implies an increase of the producti vity of the process It must be pointed out that with the publication of
and the decrease in costs thi s implies. the fi fth supplement of USP 23 on November 1996,
some chemical determ inations were revised. In this
Part II - Optimizing a Design way, the determination of the salts and the oxi di z-
able substances were eliminated and two new deter-
The des ign of the production systems for purifi ed minations introduced:
water in three European pharmaceut ica l plants was
covered in the fi rst part of this study. Th is second a. Total Organic Carbon (TOC)
part contin ues with the study, from a theoretical- b. Conducti vity
ex perimental standpoi nt, of a producti on des ign for
purified water, not on ly optimi zed from the point of Figure 4
view of obtaining better chemkal and microbiolog i- Purified Water: Comparison of the
cal qu ali ty water, but achievi ng the most economical
Determinations and Their
and simplified production system possible.
Specifications, Between European
Introd uction Pharmacopoeia (1997) and USP 23

Designing a system depends on di fferent fac tors,


Determinations .. .. .
pH 5,0-7,0
such as the quality of the feed water or the different
Chloride (mg/I) Ne(")
methods to treat or o btain the water to be introduced
Sulfate (mglt) Ne
into the system. At the same time. it depends on the
forecasted consumpt ion of watcr in the pharmaceu- Ammonia (ppm) 0,2
ti cal plant, whi ch in turn , depends on the pharma- Calciu m (mgtl) Ne
ceut ical formu lations to be prepared and the pl ant's Heavy metals (ppm) 0,01
production capacity. Oxidizable
substances Ne
The goal is a des ign to produce purified water in
Total Solids (%) 0,001
which all the factors that affect the quality of the water
have bccn takcn into account, including overall cost; Conductivity, lJs/cm
(a 25°e) 1,3
and keeping maintenance costs as low as possible.
TOC (ppb) < 500
This study includes: the study of the design (di a-
Total aerobic count
gram and descript ion of fun ctioning); chemical and (CFU/ ml) 10' 10'("")
microbiological spec ifications in accordance with t) Nc: Any physical or chemical change is produced
the European Pharmacopoe ia ( 1997 Edi tion) and the by the reaction specified in European Ph. (1997)
US P 23; critical sampling points; a report on the (00) Defined in USP 23 as action limit
design qualification; and, last ly, a recommended
samp ling schedule carried out to vali date the system Li kew ise, the publication of the eighth supple-
(PQ: Performance Qualificat ion). ment of US P 23 in 1998 eliminated the pH determ i-
nati on. Therefore, according to the eighth supple-
Chemical and Microbiological Specifications of ment, the chemi cal determinations requ ired at pre-
Pu rified Water, According to European scnt is:
P harmacopoeia (1997) a nd USP 23:
Total Organi c Carbon « 500 ppb) Conducti vity
The European Pharmacopoe ia ( 1997) and the « 1,3 -s/em at T= 2SOC).

Special Edition: Utilities Qualification 137


The European Pharmacopoeia still requires the Two clearly distinct phases were set:
determination of salts, oxidizable substances, and pH.
Microbiological specifications for purified water Phase 1: Production of purified water
determined by the European Pharmacopoeia and the Phase 2: Storage and distribution of purified
USP 23 are very similar. The only difference water to points of use
between them is that the USP 23 establishes two
kinds of limits-alert and action limits-and the Phase 1: Production of Purified Water (see Figure 5).
European Pharmacopoeia establishes only one,
which coincides with the USP 23 action limit. Production of Osmotic Water
Chlorination – flocculation – filtration –
Study of the Design: decalcification – dechlorination (by bisulfite) – 5
Diagram and description of rim filtration – W lamp – reverse osmosis.
the functioning of the system
Feed water (drinking water or from the well) is
Figures 5, 6, and 7 show the design of each system. submitted to chlorination in tank. From this tank,
water is driven along the circuit by two alternative
Description of the Functioning pumps.

Figure 5
Optimized Design (Plan 1/2)
Production of Purified Water Clean
Steam

Vent
7
FIlter
3 Silex- 5 µm
Anthracite Filter
6
1 2 Filter 3 4 5
Chloride 8
1 Detector Decalcified
Chlorination Water
Feed Tank Storage
Water Tank
2 Adding of 5 Dechlorination
Flocculant 10
Through
Return from the 4 Decalcification Bisulfite
Distribution Loop Clean Equipment
14 UV
Steam
TOC Sterile Vent
FIlter HEPA
R1: Recirculation 1
12 15
Purified
Water 11 9 8 7 6
Storage 10
Distribution
Tank 13 UV C 11 UV Reverse 9 UV
Loop
Osmosis

12
CDI: Electrodeionization C: Conductivity meter on-line
Equipment
TOC: (Total Organic Carbon)
TOC measurer on-line

138 Special Edition: Utilities Qualification


Figure 6
Optimized Design (Plan 2/2)
Storage and Distribution of Purified Water to Points of Use
16 17

19 UV
R2: Recirculation 2 HEPA Sterile
Clean TOC
Steam Vent Filter

15 11
Points of Use 18 Distribution Loop Purified
Water
Storage From
Tank Production
15 14 13 12 Plant

17 UV
16
Heat TOC: (Total Organic Carbon)
Exchanger TOC measurer on-line

When leaving the tank, the flocculant is added to tank, it flows through a 5 µm filter to retain parti-
cause a flocculation of solid matter, easing its elimi- cles which might break away from the decalcifica-
nation through filtration by silex-anthracite, the func- tion equipment.
tion of which is to retain suspended solids. The water enters the decalcified water storage
The water, once filtered, goes through decalcifica- tank, which is sterilized by clean steam.
tion equipment, which retains calcium and magne- After the water leaves the decalcified water tank
sium in the water. The equipment is made up of a and prior to it flowing into the reverse osmosis, the
double cationic resin in sodium cycle, with the aim of water flows through an ultraviolet lamp to ensure its
carrying out an automatic regeneration of resins, i.e., microbiological quality before entering the reverse
when one of these goes into a regeneration period, osmosis modules.
the other column starts functioning. This means that Water is driven by two autonomous high-pressure
it is not necessary to stop the production of purified sanitary pumps (15/20 atmospheres) into the
water to allow for the regeneration of these resins. polyamide membranes of the reverse osmosis mod-
Once the water has gone through the decalcification ules to carry out the first stage of deionization, elim-
equipment and just before it enters the decalcified water inating 95 – 97% of the salts in the water, thus
storage tank, dechlorination of the water takes place by allowing the desired quality to be attained in an eco-
injecting bisulfite into the system, avoiding the chloride nomical way.
attacking the membranes of the reverse osmosis.
As chloride, even at low concentrations, could dam- Purification of Osmotic Water
age the membranes of the reverse osmosis module, Into Purified Water
there is a chloride detector after the dechlorination mod-
ule and just before the entry of water into the decalcified Reverse osmosis – W lamp – electrodeioniza-
water storage tank. This ensures that the process is tion (CDI) – Wlamp – Purified Water storage tank.
stopped should there be a high level of chloride in the
water and thus preventing it from entering the tank. Once it has gone through the reverse osmosis, the
Prior to the water entering the decalcified water water passes the ultraviolet lamp, ensuring its micro-

Special Edition: Utilities Qualification 139


biological quality before it enters the electrodeion- In the return of the distribution loop to the puri-
ization equipment (CDI) This eliminates salts which fied water tank and before it enters the tank, the
may remain in the water after going through the water is again treated by a UV unit to ensure its
reverse osmosis modules. It should be noted that microbiological quality before arriving at the stor-
there is a conductivity meter installed on-line at the age tank. Before the water enters the purified water
exit of the CDI equipment which stops the produc- tank, there is an on-line TOC (Total Organic
tion of purified water should the specified values of Carbon) measurer that allows control of the level of
conductivity be surpassed as specified by the USP organic substances present in the purified water.
23 (1 – 3 µs/cm at T=25ºC). Another possibility to ensure the microbiological
Once it has left the electrodeionization equip- quality of the purified water to points of use consists
ment, the water flows through an ultraviolet lamp to of changing the ultraviolet treatment units by water
ensure its microbiological quality before it enters the heating to 80ºC by means of a heat exchanger.
purified water tank. Keep in mind that, in this sense, the FDA
(Guideline 1993) considers that although the use of
Phase 2: Storage and Distribution of heat could turn out to be more expensive than other
Purified Water to Points of Use systems, it does lower control and maintenance costs
(See Figures 6 and 7) and reduces potential problems in the production
system for purified water.
Purified Water storage tank – Heat exchanger
– W lamp – distribution loop – UV lamp – Recirculation
Purified Water storage tank
This design in Figure 8 shows the recirculations
The water leaves the purified water storage tank which ensure the quality of the water in case of stop-
and passes through a heat exchanger before it reach- page in the production of purified water.
es the points of use in the distribution loop. The heat
exchanger sanitizes the loop. Later, the water is dri- R1 recirculation: R1 recirculation starts after the
ven by two independent pumps to a UV unit and, ultraviolet lamp and before the purified water stor-
finally, to the distribution loop. age tank (and creates a closed circuit.)

Figure 7
Optimized Design (Plan 2/2) Storage and Distribution of
Purified Water to Points of Use – Heated Water to 80ºC

HEPA Sterile
Recirculation of
Clean TOC Vent Filter
Purified Water
Heated to 80ºC Steam
RS

Points of Use Purified


Water
Storage
Tank From
Heat
Production
Exchanger
Plant

RS: Recirculation for Sterilization of the loop with


water overheated at 121ºC
TOC: (Total Organic Carbon) TOC measurer on-line

140 Special Edition: Utilities Qualification


The installation of the ultraviolet lamp. Located R1 recirculation decreases the water level in the
in the recirculation circuit at the entry to the storage tank. When the tank reaches its minimum level, it
tank, it ensures the microbiological quality of the causes the system to start, filling the tank till it
water entering the tank. reaches its maximum level.
Rl recirculation functions during periods of non- It should be pointed out that some industrial
production, i.e., when the purified water tank is full, plants that utilize recoils coming from the reverse
during holiday periods, and during stoppages for osmosis module and electrodeionization (CDI), col-
sanitization of the distribution loop lects and recycles them. In fact, this practice is
The recirculation is continuous to avoid the risk presently being studied by the pharmaceutical
of the contamination of the water when there is no industry for application in those cases where there
production. So, when there is no demand for purified is a water shortage or in which the cost of water is
water, the water does not remain stagnant in the very high.
membranes of the reverse osmosis modules and in R2 recirculation: Recirculation in the distribu-
the resins of electrodeionization. tion loop. The water is constantly recirculating with-
Another way to avoid water remaining stagnant in the distribution loop, from the points of use to the
in the membranes of the reverse osmosis module and purified water storage tank. Stoppage of recircula-
the resins in the electrodeionization equipment dur- tion in this distribution loop is only contemplated
ing periods of production stoppage is to have the re- during holiday periods and for sanitization purposes.
verse osmosis module function cyclically for short Before starting the recirculation after stoppages in
periods of time. For example, reverse osmosis the system after holiday periods, the distribution
would start to function every two hours and do so for loop should be sterilized by clean steam at 121ºC for
10 minutes. In this way, there could be power and 60 minutes. Sanitization of the distribution loop
water saving as a result of the losses caused by the should be carried out once a month by means of
recoils in the reverse osmosis and electrodeioniza- purified water at 80ºC for 120 minutes using the heat
tion equipment. exchanger.
It should also be noted that the functioning of the The data collected during routine use will con-

Figure 8
Recirculation 1

Water Coming
from the
Decalcification 8
Equipment Decalcified 10
Water 9 UV Reverse 11 UV
Storage Osmosis
Tank

R1 Recirculation
14 UV
Vent 12 CDI
Filter
HEPA
Conductivity
C
15 Meter
Distribution Purified
Water 13 UV
Loop
Storage
Tank

Special Edition: Utilities Qualification 141


Figure 9 Figure 10

Index to Optimized Design Diagram Specifications


Description Microbiological Specifications for Purified Water
Determinations Limit
Total Aerobic Count (at 3Z'C) 10-20 UFC/ml(")
1 Tank: Chlorination E. coli No traces in 100 ml
I ; I Ps. aeruginosa No traces in 100 ml
Chemical Specifications for Purified Water
4 Decalcification Determinations
Aspect Transparent
Color Colorless
Odor Odorless
TOG(") 350-500n ppb
9 Ultraviolet I Conductivity(·") 0.5-1.3(")
~s/cm at T=25 C
D

; I • Limits of alertllimits of action: Surpassmg the alert


limit shows that the normal conditions of the
process have undergone some change. It is a
warning but does not require the corrective mea -
14 Ultraviolet I
sures to lead the process back to its normal condi -
tions .
•• According to the fifth supplement of the USP 23,
determining the conductivity replaces the determina -
tion of the different salts, and the determination of
oxidizable substances. Determination of the pH is
also eliminated according to the eighth supplement.
; I

Key Symbols Report on the Qualification of the Design


R1: Recirculation 1 (Stages: 13-14-8-9-10- The design has been conceived to attain purified
11-12-13) water in accordance with the specifi cation s of the
R2: Recirculation 2 Distribution loop European Pharmacopoe ia and the USP 23, together
Sanitary pump with the recommendations of the FDA ("Gu ide to
CjJ Sampli ng point in spect ions of high purity water systems," July
1993).
To carry out thi s optimized design, the fo ll owing
firm if the frequency of saniti zation can be factors have been taken into account quality of puri-
decreased. fied water obtained; reduction of possible incidences
Should the microbiological treatment chosen for and maintenance costs to a minimum ; factors which
the water d istribution be that of heating the water to could be engulfed in a fundam ental criteri o n:
80°C, there is no need for stoppages in rec irculation Quality Production.
in the loop for sanitization , as water c irculating al
800C is a sanitization by itself. Optimization of this design presents a series of
Another possibili ty is 10 sterili ze the loop with advantages, which are detailed as follows:
water heated to 121°C for 60 minutes. Note in Plan
212 (see Figu re 7) that to reach to sterili zation of the I. Water dech lorination by bisulfite avoids using
distribution loop, in thi s design ex ists a reci rculation carbon filters for water dechlorination , thu s avoiding
(RS) whi ch allow the pass of the Purifi ed Water the risk of microbiologi cal contamination that the
from the distribution loop through the heat exc hang- use of such filters entail s. At the same time, it repre-
er to overheat it. sen ts less ex pensive maintenance of the system, as

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142 Special Edition: Utilities Qualification
carbon filt ers need a strict and continu ous mainte- The general recirculation R I, whi ch includes
nance program. reverse osmos is and the electrode ioni zation equip-
me nt, helps ensure that, should there be a stoppage,
2. Usi ng electrode ioni zation equ ipment (COl) to the poss ibi lity of problems as a result of mi crobio-
rep lace the ionic exchange resins presents econom- logical contamination are reduced to a minimum in
ic, sa fety, and environmental advantages, as elec- the osmosis membranes and electrodeionization re-
trodeioni zation avo ids the use of the chemical solu- sins, as the water is rec ircul ating through thi s equip-
ti ons empl oyed to regenerate the resi ns of ionic ment.
exchange. Constant recircu lation of the water in R2 prevents
water from becoming stagnant in the distribu tion
3. The combined use of reverse osmos is and e lec- loop, avoiding the possib le risk of microbiol ogical
trodeionization technology full y ensures the chemi - contamination.
cal and microb iological quality of purified water
obtained in an operati ve and inex pensive way. 6. Chlorine is eliminated before the water enters
the tank of decalcified water because of R I reci rcu-
4. The use of ultraviolet lamps as di sinfectant lation. In thi s way, when recirculation is started aft er
along the system assures the microbiological quality a stoppage of the system, there is no need to dech lo-
of the water at all times. In addition, thi s method rinate constantly.
creates an advantage over the use of high-efficiency
filt ers for thi s purpose when it comes to mainte- 7. The heat exchanger has two functio ns: peri od-
nance, clean ing, and sanitization. High-efficiency ical saniti zations and regulating the water tempera-
filters have to be sterili zed periodi cally to avoid pos- tu re (not hi gher than 22°C).
sible microbiological contamination; therefore their
mainten ance makes the production of purified water 8. Note the on- line control of the conducti vity of
more ex pensive. the water when it leaves the e lectrodeioni zation
equipment. If the conductivity is over the limit set
5. Regarding the recircul ation s in the system: by the USP 23, it stops the system.

Figure 11
Microbiological Critical Points 1, 4, 5, 6, 7, 8, 9,10,11,12,15,16,17
and Points of Use
. . . . Determinations and Specifications
1 Entry of feed water into system Total aerobic at 32°C «200 CFU/ml) and
no traces of total fecal colifoms in 100 ml
4 Entry to decalcified water storage tank (8)
5 Exit of decalcified water storage tank (8)
6 Entry to reverse osmosis
7 Exit from reverse osmosis Total aerobic 50-100 CFU/ml. No traces in
100 ml of E. coli and Ps. aeruginosa
8 Ent ry into the electrodeionizalion equipment (COl)
9 Exit from electrodeionization equi pment
10 Entry into tank (8) from recirculation R1
11 Entry into purified water storage tank (15)
12 Exit from purified water tank (15), prior to UV lamp (17)
15 Entry into distribution loop, after UV lamp (17) Total aerobic 10-20 CFU/ml. No traces in
100 ml of E. coli and Ps. aeruginosa
16 Return of distribution loop, prior to UV lamp (19)
17 Return to purified water tank (15), after UV lamp (19)
Note: The fower limit IS the alert limit and the higher one IS the action limit.

Special Edition: Utilities Qualification 143


Figure 12
Chemical Critical Points 1, 4, 7, 11, 15, and 17
Point Situation Determinations and Specifications
1 Entry of feed water into system All controls: Drinking water
4 Entry to decalcified water storage tank (8) Total chloride (0.0 ppm)
7 Exit from reverse osmosis Conductivity < 150 µs/cm
11 Entry into purified water storage tank (15)
15 Entry into distribution loop, after UV lamp (17) All those determinations for Purified Water
17 Return to purified water tank (15), after UV lamp (19)

Figure 13
Weekly Sampling Criterion (Microbiological)
Points in the Total Monday Tuesday Wednesday Thursday Friday Total Points
System Points Sampled
A. Pre-Treatment 11 2 2 2 2 3 11
B. Points in Loop:
B.1 Control Points 6 1 1 1 1 2 6
B.2 Points of Use 40 8 8 8 8 8 40
In such a way that:
• Every week all the pre-treatment points and all points in the distribution ring are sampled.
• At the end of the 4 week’s validation period, four samples from each point will have been taken

9. An on-line TOC measuring apparatus is placed Introduction


in the return of the distribution loop, before the entry
of water into the purified water storage tank. It The FDA, in its 1993 Guideline, recommends
ensures that the organic substances in the water do that the validation of the system (PQ) is carried out
not exceed the specifications. in three phases. In the first and second, samples are
obtained every day, for two/four weeks at each pre-
10. R1 recirculation function:. It is convenient treatment point and at the distribution loop. The
and economical to program a 10-minute recircu- third phase consists of compiling the data attained
lation every two hours at weekend stoppages from the routinary control plan over one year.
instead of having the water circulating constant- Because of the great number of points of use and
ly. This would recoil the minimum amount of pretreatment points (before the distribution loop)
water caused by the functioning of the reverse found in pharmaceutical plants, it is very difficult to
osmosis module and in the electrodeionization comply with this FDA recommendation. Therefore,
equipment. develop a sampling plan which does not totally cor-
respond with this recommendation but which is
Recommended Sampling Plan considered to be enough to prove that the system
for the Validation operates in accordance with the established stan-
dard operating procedures (SOPs).
• Introduction
• Sampling points Sampling Points
• Microbiological sampling plan and specifica-
tions The sampling points in the system are divided
• Chemical sampling plan and specifications into two groups:

144 Special Edition: Utilities Qualification


Points in the System Prior to the Distribution Loop:
Determination and Specifications

Total Aerobic at
32"C (in CFUlml) <200 <100 <100 50-100 50-100 50-100
Total Coliforms No traces
in 100 ml
Faecal No traces
in 100 ml
E. coli No traces No traces No traces No traces No traces
in 100 ml in 100 ml in 100 ml in 100 ml in 100 ml
Ps. aeruginosa No traces No traces No traces No traces No traces
in 100 ml in 100 ml in 100 ml in 100 ml in 100 ml
( .) When two values are shown in the specifications, the first one is the alenlimit and the second one is the
action limit.

Points in the System Prior to the Distribution Loop:


Determination and Specifications

Total Aerobic at
32°C 50-100 50-100 50-100 50-100 10-20
E. coli No traces No traces No traces No traces No traces
in 100 ml in 100 ml in 100 ml in 100 ml in 100 ml
traces traces
in 100 ml in 100 ml in 100 ml in 100 ml
1 recircula tion.

A. Points in the system prior to the di stributi on 2. Ex it from tank


loop (pretreatment) 3. Entrance to the decalcification equipment
B. Points in the distri bution loop 4. Entrance to the decalcified water storage tank
B. 1 Control sampling points 5. Ex it from the decalcifi ed water storage tank
B. 2 Points of use 6. Entry into reverse osmosis
A. Points in the system prior to the di stribution 7. Ex it from reverse osmosis
l oop: (Tolal =I I points) 8. Entry in to the electrodeioni zation eq uipment
9. Ex it from the e lectrodeioni zation equi pment
I. Entrance of waler into the system 10. Entry into the decalcified water storage tank

Special Edition: Utilities Qualification 145


from RI recirculation prior to heat exchanger
II. Entry into the purified storage tank 13. Entry into the heat exchanger
14. Exit from the heat exchanger, prior to UV lamp
B. Points in the distribution loop: 15. Exit from the UV lamp, entry into distribu-
ti on loop
(6 control sampling points + 40 points of usc. 16. Rcturn ofthc distribution loop prior to UV lamp
Total = 46 points) 17. Entry into thc purifi cd watcr storage tank
after UV lamp
B. 1. Control sampling points:
B.2. Points or use (sampling points)
12. Exit from the purifi ed water storage tank As the design bein g introduced is a theoretical -

Figure 16
Points of Use of the Distribution Loop:
Determination and Specifications
B. 1 - Contro' Sampling Points

Total Aerobic at
32"<: (in CFU/ml) 10-20 10-20 10-20 10-20 10-20 10-20
E. coli No traces No traces No traces No traces No traces No traces
inl00ml in 100 ml in 100 ml in 100 ml in 100 ml in 100 ml
Ps. aeruginosa No traces No traces No traces No traces No traces No traces
in 100 ml in 100 ml in 100 ml in 100 ml in 100 ml in 100 ml
B.2 - Points of Use
Determination Points of Use: Specifications
Total Aerobic at 32"C (in CFU/ml) 10-20
E. coli No traces in 100 ml
Ps. Aeruginosa No traces in 100 ml

Figure 17
Weekly Sampling Criterion (Chemical)
Points in the
System
A. Pre-Treatment 4 4
B. Points in Loop:
B.l Control Points 2 1 1 2
B.2 Points of Use 40 8 8 8 8 8 40
a way
• Each week all the critical pre-treatment and all the critical points in the distribution loop will be sampled .
• At the end of the 4 weeks of the I will have been taken at each i.

----
146 Special Edition: Utilities Qualification
Figure 19 Determinations and spec ifi cation s.
B.I Control sampling points
Points of Use of the Distribution
Loop: Determinations Discussion
and Specifications
B. 1. - Control Sampling Points The novelties presented in this optimized design are:
Elimination of sterili zing filt ers, which are very
efficient but expensive 10 maintain, can somelimes
cause "accidents" by blockage, raising the microbi-
ologicallevel of the water (bioburden).
Introduct ion of a decalc ified and dechlorinated
Aspect Transparent Transparent water storage tank, which ensures that water enter-
ing the reverse osmosis equipment will always be
Color Colorless Colorless
chlorine-free and have a very low mkrobiallevel.
Odor Odorless Odorless Rl recirculation circuit: The decalcified water
TOe 350-500 ppb 350-500 ppb tank is the center of the R I recirculation circuit,
which ensu res that water in pretreatment wi ll con-
Conductivity 0.5-1.3 )ls/cm 0.5-1 .3 )ls/cm
stantly have a very low microbial level, which in
B.2. - Points of Use practice means obtaining purified water with a
Delenmnal10ns POints of Use: SpeCificatIOns microbial level under 5 CFU/ml.
Aspect Transparent
Presently, the function ing and control of water pro-
Color Colorless
duction systems are regulated on-line by means of spe-
Odor Odorless ci fi c software through a PLC (Programmable Logic
TOe 350-500 ppb Controller) .
Conductivity 0.5-1.3 !ls/cm
Conclusion
II. Entry into the purified water storage tank
The proposed design is easy, economical to main-
B. Points along the distribution loop tain , and ecological because it has no high-efficien-
8. 1. Control sampling points: (2) cy filters, eli minating the constant regeneration of
15 . Entry into the distribution loop, after UV lamp the ionic exchange resins. It should also be pointed
17. Return 10 the Purified Water storage tank, out that stainless steel tanks for decalc ified and puri-
after UV lamp fi ed water can be sterili zed easi ly and regularly by
B.2. Points of use: A ll (40) means of clean steam.
Therefore, validation of the system will ensure
Sampli ng is to be earned out according to the cri- the production of water will be dependable and with-
terion set oul in the follo wing table: in the specified limi ts. In this case it will be easy 10
prove that the price of the purified water will be
• Each week all critical pretreatment points and competitive and , in practice, less expensive then
all cri tical points in the distribution loop are other water-producing systems. 0
sampled .
• At the end of the four weeks of validation , four
samples will have been taken at each point.

A. Points in the system prior to the di stribution


loop: Determination s and specification s
B. Points of use of the distribution loop:

Special Edition: Utilities Qualification 147


The Ultimate
Suggested Reading
1. Faure M. Une installation d’eau purified par déminéralization,
STP Pharma Pratiques. 1991; 1 (2) 166
2. L’Acqua nell’industria Farmaceutica. Manuali Tecnici, 1st

Resource…
edition, Associazione Farmaceutici del’industria, Roma, 1991.
3. Collentro W., Angelucci L., “Coordinating Validation Re-
quirements for Pharmaceutical Water Purification Systems,”
Pharmaceutical Technology, Sept 1992, pp. 68-78.
4. Good Manufacturing Practices for Pharmaceutical Products,
Annex: Guidelines on the Validation of Manufacturing Processes.
WHO Expert Committes on Specifications for Pharmaceutical Glossary of Computerized
System and Software
Preparations, Thirty-second Report, Genova, 1992.
5. Guide of Correct Norms for the manufacture of medicine in
the European Community, Ministry of Health and Con-
sumption, General Management of Pharmacy and Sanitary
Products, General Sub-management of Pharmaceutical Development Terminology
Control, Madrid, 1992.
6. FDA, Guide to Inspections of High Purity Water Systems, July
1993. This document serves
7. Berry I.R., Nash R.A., Pharmaceutical Process Validation, as a glossary of terminol- AN
SERVICE
S•
UM U
Second Ed. Marcel/Dekker Inc. Cap 9: Ward Journal,

SA
&
F HEALTH
Validation of Water Systems for Sterile and Non Sterile ogy applicable to soft-

TO
Products, 1993: 299-317. ware development and

EN
M
RT
8. Gibes S., The Second European Pharm Tech Conference, DEPA

Barcelona, October 1994. computerized systems in Glossary of


9. Net Martinez J., “Processes for Obtaining Water-for-Injection FDA-regulated indus- Computeri
zed System
(WFI) Through Destilation,” Lifelong Training Course Les tries. It will facilitate an
Heures, Barcelona 1995. Software D d
consistency in describ- evelop
10. Validation Occupies Center Stage in GMPProposal, Drug and Terminolog ment
ing the requirements of y
GMP reports, #46. May 1996, pp. 2-3
11. United States Pharmacopeia, 23 revision: Water for Pharm- ▼
the law and regulations Reference
aceutical Purposes, Fifth Supplement, November 1996. ma
investigator terial for
12. Rosser M. FDA in Europe, Pharmaceutical Technology applicable to such s
FDA/Indus and other
try personn
el
Europe, Vol. 8, No. 11, December 1996, pp 16-21. products and systems.
13. European Pharmacopeia, 3RD Edition, Maisonneuve, SA The organization of
Sante Ruffme, 1997, pp. 808.
14. King P., “Equipment Validation: A Logical Approach to the this document is alphabetical.
Pharmaceutical Validation “Life Cycle” Journey: Part One of Acronyms are grouped at the beginning of each alpha-
a Series,” Journal of Validation Technology, Vol. 3, No. 4, betical section, and are followed by words, terms, and
1997.
15. Angelucci L., “Master Planning: How to Get Started,” Journal phrases. Acronyms are expanded at the beginning of
of Validation Technology , Vol. 3, No. 2, February 1997, pp. each alphabetical section and defined with the full
167-175.
16. Neal C., “Back to the Basics,” Journal of Validation term or phrase. The terms are defined, as much as pos-
Technology, Vol. 3 No. 3, May 1997. sible, using available standards. Over 850 terms,
17. Tisak D., Koster R., “Validation Commissioning Documents: phrases, and acronyms are included in this document.
a Checklist Approach for Facility Validation,” Journal of
Validation Technology, Vol. 3, No. 4, August 1997.
18. Flint C., Melanson P., Retzick M., Stiller S y colt, “Using a Only $29. 95
Single Sensor to Measure Conductivity and Total Organic
Carbon (TOC) in Pharmaceutical Water,” Pharm.Tech. Europe Order Today
1997. 3% On-Line Discou
19. Beaus R., Cortes F., “Design of Production and Distribution nt
Systems for Pharmaceutical Quality Waters,” Lifelong For More Information
Training Course Les Heures, Barcelona, June 1998.
20. Retzik M., “The Mesurement of Total Organic Carbon (TOC)
and Conductivity in USP 23 Grade Pharmaceutical Water,”
Call Us Today!
European Journal of Parenteral Sciences, Vol. 3 No. 1, 1998:
13-20.
21. Srikanth B., Chen Eng MS., “The Application of UV PO BOX 6004
Technology to Pharmaceutical Water Treatment,” European Duluth, MN 55806
Journal of Parenteral Sciences, Vol. 3 No. 4, 1998: 97–102
22. Bruno R., Lorenz M., “An Ambient-Temperature USPPurified Tel. 218-740-7028
Water System Using Ozone Sanitization,” Pharmaceutical U.S. Only 888-524-9922
Technology, January 1999, pp. 36-44.
Fax: 218-740-6308
E-Mail: info@ivthome.com
Web Site: www.ivthome.com

148 Special Edition: Utilities Qualification

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