Aseptic
rooms
provide sterile, aseptic and isolator environments to the current standard
focusing on key areas such as the control of microbiological contamination,
differential room pressurization, terminal filtration, easily cleanable surfaces,
controlled entry systems and airlocks, changing areas with integrated hygiene
stations with the goal of minimizing contamination by pathogens. This is designed
to integrate with containment and safety equipment.
Purpose
Aseptic technique is
employed to maximize and maintain asepsis, the absence of pathogenic organisms,
in the clinical setting. The goals of aseptic technique are to protect the
patient from infection and to prevent the spread of pathogens. Often, practices
that clean (remove dirt and other impurities), sanitize (reduce the number of
microorganisms to safe levels), or disinfect (remove most microorganisms but
not highly resistant ones) are not sufficient to prevent infection.
Importance of aseptic room in pharmaceuticals
Pharmaceuticals are
substances which contain one or more pharmacologically, therapeutically ,
active substances, derived from chemical, mineral ,plant ,microbial or animal
origin, which exhibit its therapeutic, pharmacological, chemical activity when
applied or administered to human or animal. They are be used to treat human or
animal diseases and disease conditions or symptoms.
Practice or methods adapted during and before the manufacturing of
pharmaceuticals or drug substances to ensure that the pharmaceutical or drug substance
manufactured meets highest purity quality standards, methods adapted are mostly
pertaining to Personal hygiene , and environmental cleanliness, and are to
eliminate microbial or particulate contamination or cross contamination.
Any novel, or upgraded methods or systems, operations, with respect to personal
hygiene, machinery or tools, premises or environment and its control which assures
better results with respect pharmaceutical good manufacturing practices. That
means CGMP is never a constant or a stable process rather it is continuous
phenomenon of improvement.
How aseptic room
achieves
Clean rooms fall into two
categories, unidirectional and non-unidirectional.
Unidirectional clean rooms
normally
have vertical airflow. Air
flows downwards through HEPA filters located in the ceiling. The
air is extracted through perforated flooring or grilles mounted on the walls at
floor level. Airflow
in a unidirectional clean room can also be horizontal.
Non unidirectional clean
rooms have air flows from HEPA filters located in various
positions and returned through opposite locations. Filters
may be distributed at equal intervals throughout the room or grouped over
critical areas. The distribution and
returns in this instance mean that the air flow may be turbulent in nature.
The floors, walls and
ceiling should be made of a smooth impervious material to ensure no
particle shedding and easy cleaning. They
should also be chemically resistant. All
joins in the covering materials should be welded to ensure that there is no
chance of seepage of cleaning fluids under the covering.
Doors should
be easy to open and, where necessary, two doors linked together to form an air
lock. This prevents a sudden
rush of air when a door is opened. All
doors should be controlled to prevent unwanted flow of air from one area to
another by opening of doors simultaneously.
Benches should
be made from one complete sheet of laminate because some liquids attack the
adhesive at the joints and eventually cause lifting. Where
possible made they should be made from stainless steel, which are impervious. They
are usually wall-mounted to reduce dust
collection and facilitate its detection and removal.
When storage space is
required, cupboards are preferable to drawers because they are easier to clean. Cupboards
should be dust proof and smooth inside. Rounded
beading may be used to cover dust-retaining
angles within storage spaces and between fixed benches and walls. Small
units on castors make useful additions to the working surface.
Chairs must
be adjustable and comfortable and covered with an impervious washable material.
Trolleys should
be made from stainless steel and be easily cleanable.
Switches and sockets should
be flush fitting and have plastic fingerplates.
There should be no
- Shelves,
window ledges or door frames where dust might settle.
- Pipes
or ductwork. (False ceilings
should be fully sealed with lighting recessed).
- Sinks
or drains.
Hand washing facilities should
be available external to changing rooms. Taps
should be elbow or foot operated so that cleaned hands are not used to turn the
water off. Soap should be
conveniently dispensed from a wall or bench dispenser. Electric
hand dryers or high quality paper towels should be used to dry hands.
There should be a separate
two-way transfer hatch
system for the transfer of goods in and out of the clean
room, to prevent contamination of environments.
There should be a support
room from which materials can be passed into and out of the clean room
through hatches.
There should be:
- smooth
impervious surfaces
- no
ledges for dust to gather
- surfaces
which are easy to clean
- transfer
systems/airlocks to prevent contamination
- no
water sources
How aseptic room
maintains
To maintain asepsis in the
operating room include:
- All
items in a sterile field must be sterile.
- Sterile
packages or fields are opened or created as close as possible to time of
actual use.
- Moist
areas are not considered sterile.
- Contaminated
items must be removed immediately from the sterile field.
- Gowns
are considered sterile only in the front, from chest to waist and from the
hands to slightly above the elbow.
- Tables
are considered sterile only at or above the level of the table.
- Non-sterile
items should not cross above a sterile field.
- There
should be no talking, laughing, coughing, or sneezing across a sterile
field.
- Personnel
with colds should avoid working while ill or apply a double mask.
- Edges
of sterile areas or fields (generally the outer inch) are not considered
sterile.
- When
in doubt about sterility, discard the potentially contaminated item and
begin again.
- A
safe space or margin of safety is maintained between sterile and
nonsterile objects and areas.
- When
pouring fluids, only the lip and inner cap of the pouring container is
considered sterile; the pouring container should not touch the receiving
container, and splashing should be avoided.
- Tears
in barriers and expired sterilization dates are considered breaks in
sterility.
Parental product require aseptic environment
Medications are given
parenterally to the Patients who are not able to take medications by mouth, Need
for rapid action of the medication as in emergency situations, Medication not
available in a suitable dosage form to be given by mouth, Patients with difficulty
absorbing medications. Parenteral product require aseptic environment during manufacturing,
because-
- Parenteral
administration bypasses the skin and gastrointestinal tract, the bodies
natural barriers to infection.
- Giving
a patient a contaminated product can cause serious adverse effects
including death.
- Parenteral
medications account for >40% of all medications administered in
institutional practice.
How aseptic
environment influence the quality of the product
Advanced aseptic
processing strategies offer manufacturers the best solution for protecting the
quality and safety of their products and for ensuring the highest contamination
control standards possible for products that cannot be terminally
sterilized--but it comes at a cost. Unlike terminal sterilization, aseptic processing
lines don't involve a high-heat kill step for final products, which can mute
food flavors and destroy pharmaceutical potency. But because they can't rely on
that all-powerful, microbial-destroying heat treatment, manufacturers have to
put in place strict controls, in-process control testing and validation steps
throughout the manufacturing process to ensure, that no contaminants ever find
their way into materials, components and final product.
These delicate products
can be affected not only by temperature but also light, pH balance, sheer, and
the velocity at which the product runs through a nozzle and hits the surface of
a storage container.
An advanced aseptic
process is one in which direct intervention with open product containers or
exposed product contact surfaces by operators wearing conventional clean room
garments is not required or permitted. Because, there is no opportunity to
sterilize the product in its final container.