Beruflich Dokumente
Kultur Dokumente
GOOD MANUFACTURING
PRACTICES
July 1994
GENERAL INTRODUCTION 2
I. GLOSSARY 3
III. MANUFACTURING 7
III-1. INTRODUCTION 7
III-2. ON-SITE MANUFACTURING 7
III-2.1. Water 7
III 2.2. Materials Receipt 8
III-2.3. Warehousing 8
III-2.4. Processing 8
III-2.4.1. raw materials weighing and dispensing 8
III-2.4.2. compounding 9
III-2.5. Filling and Packing Operations 9
III-2.5.1. preparation 9
III-2.5.2. filling and packing 9
III-2.5.3. distribution 10
III-3. THIRD PARTY MANUFACTURING SUBCONTRACTORS 10
III-3.1. General remarks 10
III-3.2. The Principal 10
III-3.3. The Subcontractor 10
III-3.4. Co-packer Manual 10
III-4. FINISHED PRODUCT RELEASE 11
V. LITERATURE 18
1
GENERAL INTRODUCTION
This document is intended to guide manufacturers of cosmetic products in the way they
organise and carry out the production of cosmetic products, so that human, technical
and administrative factors which may have an influence on the quality of products are
effectively controlled. The aim of this control is to reduce, eliminate and most important
of all, anticipate any deficiency in quality.
Consequently, this guide brings together all the elements to be considered inside each
manufacturing company, so that it can efficiently manufacture cosmetic products, at the
same time ensuring the safety of the user, and conform to its own pre-established
planned standards.
The COSMETIC GOOD MANUFACTURING PRACTICES set out in this guide are
particularly inspired by a total quality management system and are associated with "all
those planned and systematic actions necessary to provide adequate confidence that a
product or service will satisfy given requirements for quality".
This guide has been prepared with specific bias towards the Cosmetic Industry for which
one of the primary objectives is excellence in quality. It is limited to the manufacturing
aspect, after the product has been clearly deemed and elaborated by development. The
guide:
- encourages companies to formalise their quality assurance by proposing an
approach;
- states a number of conditions under which the different stages in the manufacturing
process should be carried out; and
- describes activities which lead to quality assurance.
It is for each company to adapt these practices to its own specific conditions. It is
accepted that some methods other than those proposed by this guide may be used,
provided that they produce a level of guarantee at least equal to those proposed by the
present recommendations.
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I. GLOSSARY
BATCH
Defined quantity, as far as it can be considered halogenous, of a raw material, a
packaging item, or a product obtained by an operation or series of operations.
In the case of an on-line manufacturing process, a batch may be the quantity produced
within a given period of time.
BATCH NUMBER
A numerical, alphabetical or alpha-numerical reference (or marking) specifically
identifying a batch.
BATCH RECORDS
All documentation related to a well defined amount of manufactured product.
BULK PRODUCT
Product which has gone through all the different stages of manufacturing, excluding
filling into primary packaging.
COMPLAINT
External information claiming a quality defect in a product.
CONPONENTS
Each element or item of packaging material which is necessary to contain the final
product and to ensure mainly its physical protection. Components are referred to as
''primary'' or ''secondary" according to whether or not they come into contact with the
product.
COMPOUNDING
All those operations which allow the prepared raw materials to be combined, according
to a defined process, and which result in bulk product.
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FINISHED PRODUCT
Product obtained after the complete manufacturing process; the product which is to be
put on the market.
IDENTIFICATION
Action or set of simple actions (as well as their results) which ensure that during a
manufacturing operation, the proper raw materials and/or the proper components are
used; identification is however no guarantee of quality compliance.
MANUFACTURING
Set of operations of a technical nature (transformation of supplied products, processing,
filling and packing, warehousing, maintenance, checks, inspection...) necessary to
obtain the finished product, as well as any related administrative and economic
operations.
MANUFACTURING INSTRUCTIONS
Documents which describe in detail operations related to a specific product.
PROCESSING
All operations of a technical nature involved in producing bulk products.
RAW MATERIAL
Any substance going into or involved in the processing of a bulk product.
RECALL
Decision taken by a company to call back a product batch which has been put on the
market.
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RETURN
Movement of one or several products which have been put on the market coming back
to the production site.
SAMPLING
Set of operations related to the taking and preparation of samples.
SCHEDULE OF SPECIFICATIONS
A collection of the different specifications and requirements concerning a product, a
piece of equipment or a service laid down by the client for the benefit of the supplier.
SEMI-FINISHED PRODUCT
Product obtained after primary packaging, requiring at least one further operation before
it can be considered as a finished product.
SUBCONTRACTING
Carrying out by an outside person or organisation (the subcontractor) of an operation on
behalf of a person, a company or organisation (the principal).
II-1. INTRODUCTION
To reach the objectives which a company has set itself, it should design, set up and
maintain a quality system which is adapted to its activities and the nature of its products.
At the production level, this consists of a complete system including organisational
structure, responsibilities, available resources, procedures and processes, in order to
implement quality management.
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II-3. RESOURCES
The company should be able to rely on adequate and appropriate resources as far as
personnel, premises, equipment and machinery are concerned.
II-3.1. PERSONNEL
Each firm, according to the amount and diversity of its production, should set up an
organisational structure and should employ adequate staff in the different fields of
activity; they should be persons whose knowledge, experience, competence and
motivation are adapted to the tasks and responsibilities which they are given.
II-4. PROCEDURES
Each company should set up its own system of procedures and manufacturing
instructions bearing in mind the nature of its production and the organisational structure
it has decided upon.
Procedures and manufacturing instructions should be suitably defined and formalised;
they describe in detail operations to be carried out, precautions to be taken and
measures to be applied in the different activities connected with production.
II-5. PROCESSES
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III. MANUFACTURING
III-1. INTRODUCTION
For each stage of production, measures should be planned and effectively carried out in
order to guarantee that the essential conditions for ensuring conformity are met.
All arrangements should be made for applying and complying with procedures and
instructions relative to each stage of the process. At any given moment it should be
possible to identify a piece of equipment, an instrument, a raw material, a component, a
consumable substance, e.g. cleaning products, or a document.
Any substance other than raw materials and bulk products should not and cannot be
confused with the above in order to avoid contamination.
The company may either carry out all production operations itself (on-site production) or,
for certain operations, resort to subcontracting (off-site production).
Staff should have instructions, information and data for on-line or work-station
operations, for product marking and its nomenclature, for servicing of equipment
(emptying, draining, cleaning, disinfecting...) and for packing operations.
III-2.1. WATER
- Water production equipment and water systems should always supply a quality of
water which guarantees conformity of the finished product.
- Water systems should allow disinfection in conformity with well established
procedures.
- Pipework should be built to avoid stagnation and risks of contamination.
- Materials should be chosen so that water quality is not affected.
Suitable markings should allow identification of water pipes such as hot, cold,
demineralised water, cleaning water or steam.
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III-2.2. MATERIALS RECEIPT
The receipt of all goods intended for profusion (raw materials, components, bulk
products...) should follow an established procedure; each delivery should be recorded
and its conformity carefully checked.
Sampling should be taken by authorised and skilled persons in order to guarantee that
the withdrawn samples always correspond to the delivered batch both in identity and
quality.
III-2.3. WAREHOUSING
All materials essential for manufacturing as well as finished goods, should be stored in
proper conditions according to their nature and in an orderly manner to ensure efficient
batch identification and stock rotation. A system should be set up to prevent any
unacceptable material from being used.
III-2.4. PROCESSING
Whatever the organisation on the production site, all raw materials for compounding
should be identified and quantified according to the product formula.
These raw materials should be measured, weighed and proportioned either into clean
adequate recipients containing the necessary information, or directly into the machinery
or equipment for compounding, whether this is done according to a continuous or
discontinuous process. During weighing of raw materials, suitable arrangements should
be made to avoid cross-contamination. After weighing, all raw material containers
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(external packaging, recipients...) should be placed or replaced to avoid any risk of raw
material alteration.
III-2.4.2. Compounding
All compounding requires a formula as well as detailed rules of manufacturing, for each
product, for the batch quantity and for the machinery used.
III-2.5.1. Preparation
Whatever the organisation for filling and packing, all essential components including bulk
products should be effectively and correctly identified.
It is also important that there should be no risk of presence or contact of any packaging
component or product from any previous filling or packing operation to avoid any mixing
with the components of tile product to be packed or the product itself.
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All instructions concerning packing operations, sampling or checks should be available
before commencing the operation.
III-2.5.3. Distribution
Procedures for shipping should exist, in order to ensure that conditions necessary for
maintaining product quality are respected.
Before being put on the market, all finished products must conform to standards.
It is the responsibility of the principal to assess the subcontractor's ability to carry out the
appropriate operations and to ensure that he has the necessary facilities available in his
company (personnel, premises, machinery, quality assurance...). If this is the case, the
principal should provide the subcontractor with all requisite information, for example by
means of a written contract giving details of their respective responsibilities in the
manufacturing stages concerned.
The subcontractor should respect the pre-established formal terms and conditions.
He should pay particular attention to the technical requirements which have been agreed
upon. He should facilitate any checks and audits that the principal may request.
Procedures and specifications should be drawn up between the principal and the
subcontractor in order to define respective responsibilities for the manufacture of the
product. Technical aspects of specifications should be agreed upon by competent
personnel well trained in Good Manufacturing Practices.
Specifications should make provisions for measures authorising the principal to carry out
audits to ensure that Good Manufacturing Practices are implemented.
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III-4. FINISHED PRODUCT RELEASE
A recognised acceptance act is necessary before finished products are put on the
market, in order to prove their conformity. Different methods for delivering this act are
possible according to the nature of the product, the quality system and the type of
production used.
Products may not be put on the market until effectively released by the principal.
This acceptance must be made following a procedure in clearly defined terms. These
terms may be mentioned in the subcontracting agreement.
IV-1. INTRODUCTION
In order to reduce, eliminate and more importantly to preclude any deficiency in quality,
a whole set of activities should be carried out, both by the manufacturing department
itself and by other departments directly or indirectly linked to manufacturing.
IV-2. MANUFACTURING
It concerns:
- raw materials and components purchased from suppliers, and where applicable
manufacturing machinery,
- partial or total subcontracting of packing operations such as filling,
- partial or total subcontracting of product manufacture, for example by a specialised
company.
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It is essential that all qualitative demands should be specified in close collaboration with
the departments concerned, which could be Research and Developments,
Manufacturing, Quality Assurance.
Responsibilities for the main activities should be clearly deemed, for example:
- setting specifications for raw materials, components, etc.
- approving suppliers and subcontractors for quality assurance,
- setting conditions for customer-supplier relations and exchanges (assistance,
audit,...)
- taking into account inspections carried out by the supplier or the subcontractor,
- drawing up contractual technical clauses (type of inspection to be carried out, criteria
for acceptance or refusal steps to be taken in case of non-conformity or
modifications...),
- any other demands, such as for example, price, delivery times and instructions, or
after-sales service if necessary.
Purchasing documents:
Records of every operation carried out on this machinery should be kept according to
local customs or requirement. For weighing apparatus on production machinery, regular
calibration of measurement instruments should be made.
Generally speaking, the department, whether inside or outside the company which has
developed the product (formula and packaging), should also provide at least a pilot
process, taking into consideration these cosmetic GMP requirements.
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Processing, filling and packing operations should follow well-defined and tested
procedures.
A formalised process should exist according to the nature of the product, the size and
structure of the company, which leads to an industrial process.
For the Cosmetic Industry, a finished product should neither adversely affect the health
of the consumer, nor undergo any deterioration in quality due to the presence or
multiplication of micro-organisms in the product. In order to achieve this, it is essential to
comply with good hygiene practices.
In all sectors of the factory, it is essential to keep building, equipment machinery and
instruments, as well as raw materials, components, bulk and finished products in good
hygienic conditions.
Generally speaking, the different activities concerned are the manufacturing area, which
should be organised so as to avoid any risk of standing water, dust in the atmosphere,
presence of insects and other animals. Filling and packing equipment should be cleaned
and disinfected according to their design and use.
The personnel should respect specific practices as far as personal hygiene is concerned
and follow instructions as to how to work and carry out operations.
It is important to identify the source and the nature of any contamination likely to appear
and to take steps to eliminate these sources in order to prevent product contamination.
By quality control operations, are meant all operations carried out with a view to
monitoring quality compliance during manufacturing.
Concerning the different operations, we can divide them into two groups:
- First, control of incoming goods and final control of finished products are the
responsibility of laboratory personnel,
- Second, process control during manufacturing is the responsibility of manufacturing
personnel.
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In order to carry out these control operations efficiently, both laboratories and
manufacturing personnel should have available the following information:
- specifications,
- sampling procedures,
- inspection and test methods,
- acceptance limits.
Results obtained should be endorsed, used and recorded. These records should contain
at least the following data:
- results of inspections, measurement or checks, as well as any remarks by staff
having carried out the operations,
- in the specific case of approving, the situation should be clearly stated: approved,
rejected, pending.
Any type of filling system may be used, on condition that documents can be rapidly
consulted, reproduced and kept in good condition.
Sufficient quantities of raw material samples corresponding to each batch used should
be kept, so that complete analyses can be made; the same conditions apply to each
batch of finished products which should be kept in their packaging. All these identified
samples should be stored in limited access areas which are specifically intended for this
purpose (sample library).
IV-8. TRAINING
Bearing in mind the know-how and the experience of a given section of personnel,
training courses adapted to their jobs and responsibilities should be drawn up and
implemented. Consequently, for example complete training is essential for all key
personnel and manufacturing personnel concerning the methods and competence
required to carry out different operations (e.g. weighing, compounding maintenance,
industrial hygiene, manufacturing, in-line checks…).
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According to the means and resources available inside each company, these training
courses may either be devised by the company itself or with the help of outside
specialised organisations following a programme which should be worked out case by
case.
At all events, this plan should be regularly reviewed and followed up.
IV-9. DOCUMENTS
In order to avoid errors which may arise from spoken communication discrepancies, lack
of precision, forgetfulness, documents are indispensable.
The procedure should clearly define the type of any modifications and the responsible
persons concerned; it should mention the reasons and the date.
All documentation should be regularly revised and updated taking care to withdraw
immediately any out-of-date document. An inventory of documents existing inside the
company should be kept up-to-date.
IV-9.1. PROCEDURES
General guidelines for operations to be carried out should be given. For example,
procedures may concern the following:
- sampling of raw materials and components,
- manufacturing processes, filling and packaging methods, inspection methods for
machinery and equipment,
- cleaning and/or disinfecting premises and machinery used during manufacturing,
- actions to be carried out before commencing any production operation, for example
line emptying,
- measures to be taken and methods to be followed due to non-conformity of
components, raw materials, bulk products, finished products…,
- calibration of measuring instruments,
- product recall.
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IV-9.2. RULES OF MANUFACTURING
For proper manufacturing, it is essential that precise rules are defined for all possible
operations.
IV-9.3. SPECIFICATIONS
Specifications should describe requirements with which all raw materials, component,
bulk products, semi-finished and finished products used or obtained during manufacture
have to comply.
In order to carry out necessary investigations efficiently, within the framework of possible
incidents encountered concerning the quality of a product batch, it is essential to record
the processing and packing data for each batch and to ensure the batch traceability.
Records and monitoring operations should be made at each production stage and
should concern, for example:
- measurements and tests made during manufacturing and packing,
- data given by automated processing and checking equipment,
- remarks and observations made by processing and packing staff during production.
These documents may either be kept together in one place or left in the different
departments concerned, for consultation.
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IV-10. MONITORING AND USE OF RESULTS
With the help of this information, an analysis of probable causes for defects should be
made in order to decide on corrective actions to be carried out.
In case of complaint, only justified complaints will be considered and connected with
batch record. It should be recorded, sent to the departments concerned, an analysis of
the causes made, and if necessary, corrective actions should be carried out.
The aim of the audits is to ensure conformity with Cosmetic Good Manufacturing
Practices and if necessary to propose corrective actions.
The results of audits should be sent to the management of the company and
communicated to the audited personnel, so that they can take part in setting up actions
for improvement. Checks should be made that corrective action has been taken.
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V. LITERATURE
ISO 8 402
Quality - vocabulary
ISO 9 001
Quality systems - Model for Quality Assurance in design development, production
installation and servicing
ISO 9 004
Quality management and quality system elements – Guidelines
The rules governing medicinal products in the European Community - Guide to Good
Manufacturing Practices for medicinal products - vol. IV ; 1989.
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COLIPA , THE EUROPEAN COSMETIC, TOILETRY AND PERFUMERY
ASSOCIATION, was set up in 1962 under Belgian law with headquarters in Brussels.
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