Risk Analysis in Case of Insufficient Process Validation

The topic of "risk" appears 16 times in FDA's Process Validation Guidance. Annex 15 to the EU GMP Guidance clearly states: "As part of a quality risk management system, decisions on the scope and extent of qualification and validation should be based on a justified and documented risk assessment of the facilities, equipment, utilities and processes." In their guidance, the FDA also recommends a risk-based approach to determining critical parameters. But how should inadequately validated processes be handled in retrospect? The FDA comments on this in a recent Warning Letter.

The FDA criticized Outin Futures Corp. for failing to validate the homogeneity of the API in an intermediate for its over-the-counter (OTC) drugs. Deficiencies in the cleaning validation were also criticized.

In response, Outin sent a validation protocol to the FDA to demonstrate the homogeneity of the active ingredient. A validation protocol for cleaning validation was also included in the response letter.

However, the FDA found that Outin omitted a risk analysis of the batches already distributed without adequate process validation. The specification of the acceptance criterion for cleaning validation was also insufficient. In addition, there was no cleaning method validation to demonstrate API recovery.

Further FDA requests

The FDA further requests an evaluation of each medicinal product to ensure that a scientific and data-driven program is in place to identify and control all causes of process variability in order to meet specifications and manufacturing standards. This includes the qualification of equipment, sufficient detectability of monitoring and testing systems, the quality of input materials and the reliability of each manufacturing step.

Improvements in the cleaning validation program are also required, with particular emphasis on worst case scenarios in pharmaceutical manufacturing. This applies in particular to the identification and evaluation of worst cases: 

• drugs with higher toxicities
• drugs with higher drug potencies
• drugs of lower solubility in their cleaning solvents
• drugs with characteristics that make them difficult to clean
• swabbing locations for areas that are most difficult to clean
• maximum hold times before cleaning

In addition, the FDA requires:

• An overview of the updated operating procedures that ensure an appropriate cleaning process verification and validation program are in place for products, processes and equipment.
• A description of the steps that still need to be implemented in the change management system before new equipment or a new product is introduced.

Conclusion: Risk analyses should not only be used prospectively before validation, but also retrospectively if processes have not been fully validated.

As always, you can find the entire Warning Letter on the FDA website.