pm1210_holistic_west_final.pdf
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Sponsored by
WWW.PHARMAMANUFACTURING.COM
Holistic
QbD
Holistic Qb
Developing a Qb
Componen
The Lifecycle
Syringe Plung
QbD for Pharm
Packagin
Componen
Next Pag
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Since FDA introduced the term to the pharma-
ceutical industry in 2005, the concept o phar-
maceutical Quality by Design (pharma QbD), a
ramework or building quality into pharmaceu-
ticals during drug development has been slowly
gaining ground. Today, the leading name branddrug companies and a number o generic drug
manuacturers are using Quality by Design meth-
ods to optimize product development. Case
studies have been published or solid dosage
orms; biopharmaceuticals; and even, on a pre-
liminary basis, or vaccines.
The concepts behind QbD grew out o work
published decades ago by such quality experts
as Joseph Juran. They have been used in other
industries or some time, but pharmaceutical
manuacturers are now applying them to ensure
consistent product quality despite variations in
raw materials and other variables.
Discrete industries are no strangers to QbD.
Now, however, some vendors to the pharma-
ceutical industries are applying pharma QbD
principles to develop their pharmaceutical in-
dustry products. This e-book oers general
resources in the area o QbD, and discusses
how West has been bringing a QbD approach
to its packaging components. We hope that
you ind it useul.
2
Contents3 Holistic QbD
by Andy Polywacz, VP o QA,Americas, West Pharmaceutical
Services
6 Developing a QbDComponent:The Liecycle oSyringe Plungerby Tibor Hlobik, director, Global
Prellable Syringe Platorm,West Pharmaceutical Services, Inc.
9 QbD or PharmaPackagingComponentsby Paul Thomas, senior editor,
Witt-Kieer
13 Online Resources
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Modern GMP expectations are transorm-
ing the way drug products are being devel-
oped, manuactured, evaluated and con-
trolled. The movement rom ascertaining
drug product quality predominantly by end
product testing to achieving quality by de-
sign (QbD) or eective and ecient manu-
acturing processes is reinventing the GMP
landscape. Harmonized guidances associ-
ated with pharmaceutical development,quality risk management and pharmaceuti-
cal quality systems (ICH Q8, 9 and 10) have
initiated a ramework or science-based
quality manuacturing.
The goal during development is to have pre-
dened objectives with emphasis on the
product and understanding the manuac-
turing process; controls are then based on
knowledge to build the manuacturing sci-
ence while employing quality risk manage-ment principles. Drug product ormulation
development summaries should highlight
the evolution rom initial concept to nal de-
sign and take into consideration the choice o
drug product container closure systems.1 An
in-depth understanding o container closure
components along with their manuacturing
process will enable science-based decisions to
support pharmaceutical manuacturing con-
trol strategies. Aspects o container closure
systems critical to drug product quality can
be established during the drug development
cycle by identiying potential attributes o the
component and utilizing various risk
management tools to evaluate risks.
The level and ormality o risk as-
sessments should be commensurate
with the level o risk to drug product
quality.2 It is possible to combine and coor-
dinate process knowledge rom multiple unit
operations to achieve a holistic picture o the
entire drug manuacturing process, which can
incorporate the science o component manu-
acture. A mechanistic understanding o how
drug ormulation and component manuac-
turing process actors aect pharmaceutical
quality will lead to:
Eectieteclytatwillreduceset-
backs when moving rom development to
commercialization, realizing time and cost
savings
Data-driekwledetidetifycriti-
cal quality attributes and establish control
strategies
H Qay by DegnBy Andy Polywacz, vice president, Quality Assurance,Americas, West Pharmaceutical Services, Inc.
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Specicatisbasedwadwyte
rubber ormulations, components and pro-
cess actors impact drug product quality
Beetstruuttelifecyclefa
given product through trending o data or
proactive management and eective con-
tinuous improvements
West NovaPure elastomeric components
are ormulated and manuactured using
a QbD approach that is holistic in nature.
This approach takes into consideration
the entire supply chain rom raw materials
through distribution and drug packaging.
Quality characteristics are engineered to
meet the requirements o the pharmaceuti-
cal manuacturer and help promote protec-
tion/compatibility o drug product.
The ollowing important QbD elements were
used to develop and produce NovaPure
components with a commitment toward en-
hancing drug product quality:
QualityTaretPrductPrle(QTPP)
CriticalQualityAttribute(CQA)
QualityRiskMaaemet(QRM)
KwledeMaaemet(KM)
CriticalPrcessParameter(CPP) CtrlStratey(CS)
LifecycleMaaemet(LCM)
CtiuusImpremet(CI)
Consideration o all these actors during
development o NovaPure components
has achieved a well-understood compo-
nent and robust processes that 1) deliver
a component meeting the QTPP and 2)
are controlled by dened steps within the
manuacturing process. During commer-cial-scale manuacturing, the proactive
trending o component perormance on
a continuous basis provides a major ad-
vantage through early detection o poten-
tial issues and urther optimization o the
control strategy to ensure reliable level o
high-quality components.
The holistic approach to the development
o NovaPure components encompassed the
actors associated with raw materials, as well
as manuacturing process parameters re-
lated to multiple acets o component qual-
ity. A cross-unctional team o subject matter
experts was employed to dene the scopeo the risk assessments and quality attributes
to be evaluated. The risks were sorted and
ranked based on the relative criticality o the
various properties and attributes o the com-
ponent. The analysis o unctional relation-
ships distinguished the level o risk and pri-
oritized relevant studies to evaluate risk.
Manuacturing trials were conducted to as-
sess quantitatively the relationship between
process parameters and identiying CQAs.Desifexperimets(DE)quatitatiely
predicted the eects o process parameters
on quality attributes and multivariate analy-
sis was employed to predict interaction o
multiple process parameters, reducing un-
certainty o areas having the greatest im-
pact to component quality. Critical process
parameters were identied through ull ac-
torial analysis so that interactions o multiple
process parameters were established within
a given range or particular componentquality attributes. As multiple parameters
were simultaneously examined to under-
stand interactions between actors, an e-
cient process to acquire and analyze data
with higher precision or component qual-
ity was achieved. The acquired data led to
a well-understood component and revealed
the sources o process and component vari-
ability to be monitored and controlled. As
holistic QbD practices were implemented
or NovaPure components, upstream con-trols were put in place rather than quality
by conormance related to capability o the
process based on discrete actions.
The demands o drug product regulation
continue to evolve as a result o the increas-
ingly global economy in which the supply
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chain has become central to assuring drug
product quality. Qualication and procure-
ment o raw materials or NovaPure com-
ponents is initiated at concept develop-
ment, employing risked-based assessment
to achieve the desired component quality.
Vendor quality and business practices areevaluated to ensure reliable supply o raw
materials. These materials are proled to
understand variability and enable control
strategies. Monitoring raw materials used to
manuacture NovaPure components secures
the inventory through enhanced component
and process understanding. Assurance o
a reliable and readily available inventory is
an important consideration or preservation
o marketed drug product supply; a holistic
QbD process or components contributesto this aspect. Additionally, other aspects o
supply chain are considered relating to mini-
mized, standardized lead time or commer-
cial volumes, immediate shipment or small
volumes and aspects o supply chain secu-
rity built into the shipping cartons to rein-
orce tamper evidence.
The quality management system was tied
into the data starting at development stages
enabling science-based decisions to develop-ment o control strategies. Activities were o-
cused on maintaining component quality as a
result o knowledge gained to support CQAs
and impact to the manuacturing process.
Procedures were optimized or testing and
analysis to develop specications to maintain
a state o control and produce reliable com-
ponent quality. Scientic data that supported
control strategies are evaluated continually
and include annual reviews, considerations o
investigations and complaints to enhance un-derstanding o component and process.
A distinguishing eature o NovaPure com-
ponents is that attributes are assured
based on identication and control o criti-
cal process parameters (CPP) rather than a
rigid, static manuacturing operation that is
more susceptible to multiple manuactur-
ing changes. Current regulatory expecta-
tions are to have reduced uncertainty using
data-supported evidence o suitable com-
ponents during development through com-
mercialization. The variability o NovaPure
components has been minimized throughscientic-based assessments and is veried
continuously with a course o action or con-
tinuous improvement.
Most importantly, the NovaPure brand pro-
vides a shared quality commitment with
pharmaceutical manuacturers, allowing
greater predictability o component per-
ormance, which can contribute to achiev-
ing drug product with the quality attributes
appropriate to meet the needs o patients,health care proessionals, regulatory au-
thorities and internal customer require-
ments. Transparency between pharmaceu-
tical manuacturer and component supplier
is realized through managing knowledge
that is grounded in the nuances and com-
plexities revealed through implementing
holistic QbD. Included in this model is a
24/7 customer support knowledge center
to provide comprehensive inormation on
the NovaPure product and QbD processes.The transition rom the GMP era o qual-
ity management through checkbox compli-
ance to science-driven assessment and jus-
tications can be acilitated greatly through
use o NovaPure components; a reliable
supply o high-quality sterile components
in a ready-to-use ormat.
Reerene1 Guidance for Industry: Q8 (R2) Pharmaceu-
tical Development Revision 2, US Depart-ment of Health and Human Services Food
and Drug Administration, CDER/CBER, ICH
November, 2009.2 Guidance for Industry: Q9 Risk Manage-
ment, US Department of Health and Human
Services Food and Drug Administration
CDER/CBER, ICH June 2006.
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DEvELoPIngAQbDCoMPonEnT:
the leye
syrnge PngerBy Tibor Hlobik, director, Global Prellable Syringe Platorm,West Pharmaceutical Services, Inc.
Market trends toward home-use and patient sel-administration o drugs
used to treat chronic conditions (e.g., multiple sclerosis, rheumatoid ar-
thritis and autoimmune) have made prellable syringe systems an ideal
choice or single-dose drugs. Prelled syringe systems or vaccines,
pharmaceuticals and biopharmaceuticals oer convenient, xed dosing
and are adaptable to automated injection devices.
For patients, use o a prelled syringe system has the potential to
minimize microbial contamination and reduce medication dosing
errors. The syringe systems oer ease o use and enhanced con-
venience or those who require requent dosing, and when com-
bined with an auto-injector system, can provide a more portable
drug delivery system.
Pharmaceutical and biopharmaceutical manuacturers who se-
lect a prellable syringe system or their drug product may be
able to reduce therapy and injection costs, as well as signi-
cantly reduce overll when compared to single-dose vials.
The system may also optimize the number o doses rom
the existing drug supply, while oering a delivery option
that will help to dierentiate the system in a crowded
market and potentially increase patient preerence.
Strategies employed in early phases o drug develop-
ment that consider delivery devices such as prell-
able syringes and their components can mitigate
risk to quality, and position the product to meet
needs o the ongoing drug product liecycle. The
return on investment can be realized once a drug
product is commercialized and has gained pa-
tient loyalty through ease o use, therapeu-
tic benet and high condence in the delivery
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device. While it is not easy to meet these
challenges, a drug product manuacturer
can benet rom early investment in the
right drug delivery system and high-qual-
ity components.
Hgh-Qay cmpnen Faae
Efen Manarng
Most subcutaneous drug product injections
utilize a staked needle 1mL long prelled
syringe ormat that can retain a ll volume
1.0mL. This syringe ormat is convenient,
ts most auto-injectors and is widely usedor sensitive pharmaceutical and biotechnol-
ogy drug applications.
The use o high-quality components in pre-
llable syringe systems will acilitate ecient
manuacturing processes and support a reli-
able supply o drug products. An elastomeric
plunger is a critical element because it serves
as the primary seal or container closure in-
tegrity, maintains purity o drugs during shel
lie, and unctions to expel contents o thebarrel and deliver drugs to the patient.
Plungers (also named pistons and stoppers)
are typically made rom butyl rubber and
can be coated with a fuoropolymer lm,
such as FluroTec lm, that can increase lu-
bricity and serve as a barrier between the
drug and the elastomer, reducing the poten-
tial or extractables inherent in all materi-
als. The phenomena o chemicals migrating
rom the elastomers into the drug prod-uct is known as leachables, but the reverse
process o the drug product adsorbing or
absorbing onto the plunger can also occur.
Extractablesadleacablescabesii-
cantly reduced with a barrier lm.
For improved manuacturing processes, the
pharmaceutical industry has moved toward
ready-to-use (RU) plungers or prellable
syringe systems. These components are
washed and sterilized prior to delivery to the
drug manuacturer with specications or
particulate and endotoxin, thereby reducing
the risk o introducing microbiological con-
tamination to the drug product during nal
packaging. There are several methods orsterilization o plungers and an increase in
extractable breakdown products have been
observed under gamma radiation; thereore,
autoclave steam sterilization o these com-
ponents is a preerred choice.
Qay by Degn: A New Way Mee
inreang Regary and Qay
Reqremen
Quality by Design (QbD) promotes under-
standing o the product and manuacturingprocess starting with product development.
When designing and developing a product
using QbD principles, manuacturers must
dene desired product perormance and
identiy Critical Quality Attributes (CQAs).
The product and process is then designed
to meet those product attributes, which
leads to understanding the impact o ma-
terial attributes and process parameters
on the CQAs and identication and control
o sources o variability. As a result o thisknowledge, a company can continually mon-
itor and update its manuacturing process to
assure consistent product quality.
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Since prelled syringes are considered a
combination product, which is dened
by the agencies as A product comprised
o any combination o a drug and device; a
device and biological product; a biological
product and a drug, or a drug, a device and
biological product, two regulations apply:
cgMPFiisedParmaceuticalspart21
CFR 210-211
QSRReulatifrDeices21CFR820
Some o the primary areas covered by CFR
820 and that dier rom CFR 210-211 in-
clude management responsibility, purchas-
ing controls, corrective and preventive
action and design controls. As part o the
industrialization o plungers using the QbD
approach, aspects o CFR 820 must be in-
corporated into the manuacturing process.
Plungers that it 1mL long staked needle
syringes were originally developed or a
manual injection action. As customer de-
mand or higher quality and patient need
or sel-injection have evolved, demand
or a high-quality plunger rose. Using QbD
principles, West developed its NovaPure
components or preillable syringe sys-
tems to provide high reliability or break-
loose and glide orce, dimensional consis-
tency, sub-visible and visible particulate
control, and low parts per million (ppm)
deect attributes.
The 1mL long NovaPure plunger ollowed
a development liecycle program, which
used a Quality Target Product Proile
(QTPP) to establish CQAs or control o
breakloose and glide orces. As the prod-
uct which included risk-based design
iputs,FiiteElemetAalysis(FEA)
modeling, data generation on multiple
concepts, and inal product perormance
veriication with glass barrels rom mul-
tiple suppliers o a 1mL long staked nee-
dle syringe was developed, the QTPP
served as a guideline to assure that tar-
geted speciication values or breakloose
and glide orce were met.
Using QbD philosophy and principles can
help to optimize breakloose and glide
orces and signicantly reduce plunger
variation rom part-to-part. Use o QbD
principles ensures that components are
developed based on science and data-
driven decisions, as well as meet critical
specication or deects, visible and sub-
visible particulate and extractables con-
sistently. In order to achieve a high-qual-
ity product, QbD components are washed
and steam sterilized or optimized material
compatibility and the knowledge gained
throughout the process used on an ongo-
ing basis to maintain continuous improve-
ment by the manuacturer. Selecting a
manuacturing partner like West early in
the development process can help phar-
maceutical companies choose a high-qual-
ity component or use in prellable syringe
systems that will meet demands or high
quality, improved total cost, and increased
saety and security or the drug product.
NovaPure and FluroTec are registered trade-
marks of West Pharmaceutical Services, Inc.,
in the United States and other jurisdictions.
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At the PDA Annual Meeting
in Phoenix in April 2012, West
Pharmaceutical Services rein-
troduced its NovaPure line o
drug packaging components
including serum and lyophili-
zation stoppers and syringe
plungers. What is unique
about the new NovaPure is
that, or the products design
and development, West lever-
aged the principles o Qual-
ity by Design. West has long
viewed itsel as a supporter
o the industrys QbD eorts,
but has now taken that sup-
port one step urther. Its a
vast change rom the way the
company developed prod-
ucts in the past, and may be
seen as a sign that the infu-
ence o Quality by Design is
expanding beyond drug and
device manuacturing and
taking root in the vendor and
solution provider community
as well. (West has posted a
video on YouTube with more
details on how QbD played
into the development o No-
vaPure.)
In anticipation o the Nova-
Pure announcement, we spoke
with Fran DeGrazio, Wests
vice president or marketing
and strategic business devel-
opment. DeGrazio has nearly
30 years o experience in the
industry, is a requent speaker
and author on pharmaceutical
packaging and injectable drug
products, and is a member o
PDA, ACS and AAPS.
9
QbDFoRPhARMAPACKAgIngCoMPonEnTS:
A sn Prvder Ge
Mre sene-BaedBy Paul Thomas, senior editor, Witt-Kieer
ViDEo NovaPure Components
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PharmaQbD: How did the idea o apply-
ing Quality by Design to the manuacture o
components arise? What drove this initiative
rom a business perspective?
FlD: West initiated an intensive Voice o the
Customer process several years ago to en-
gage directly with key customers to identiy
and assure that our direction and resource
investments would correlate to the needs o
our customers. As a result o that engage-
ment, we provided guidance to R&D, Opera-
tions and other unctions on customer ex-pectations. Although Quality by Design was
never directly mentioned by a customer at
that point, what was conveyed was the act
that we needed a better understanding o
our customers challenges and the perspec-
tive o what they need to deal with rom a
regulatory and end-user standpoint.
As we do try to stay very close to the mar-
ket and regulatory issues, we identied
Quality by Design as a way to provide aproduct with improved understanding and
less variability to our customers. We elt this
was the ultimate eort to put ourselves in
their shoes.
PharmaQbD:Where did you begin the pro-
cess? Who took the lead, and how challeng-
ing were the training and other eorts to get
buy-in rom all involved?
FlD: The key to this program is that it ismulti-disciplinary i it is executed correctly.
Initially this requirement was dened by our
Marketing organization, but our R&D group
quickly picked up the banner to help drive
the program, along with our Operations and
Quality organizations. It was exciting to see
the understanding as people engaged ur-
ther with the program and could see the re-
sults and benets.
The training or the organization has been
intensive. O course, those directly in-
volved with the development and manu-
acture had more intensive training than
those in the support areas. However, the
entire organization has received training
on Quality by Design rom the pharma-
ceutical market perspective and how West
has approached this initiative with our new
West NovaPure brand.
PharmaQbD: What was the biggest de-
parture rom your previous manuacturing
methods? In what ways were the old meth-
ods non-QbD-like, i you will?
FlD: The biggest change is a total reliance
on data and science-based decisions versus
a reliance on experience. At West we have
many long-term employees who add value
on a daily basis because o their experience.Our tendency in the past, however, was to
rely too heavily on this aspect in both de-
velopment and problem resolution. QbD is
driven systematically through the genera-
tion o data, so you are working based on
acts and not assumptions.
PharmaQbD:Lets take extractables and
leachables as an example. How did you ad-
dress them dierently in a QbD context?
FlD: In respect o extractables, we have
taken a multi-pronged approach: First, we
have developed the VeriSure technical pack-
age. This technical package provides in-
depth extractables data to our customers
and allows them to move into leachables
testing more quickly.
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Second, using the VeriSure technical pack-
age, we have conducted our own risk as-sessment o the identied extractables in
order to study and evaluate anything that
may be considered high risk.
Third, as a part o the NovaPure product,
we provide a lot-by-lot extractables nger-
print. This is in addition to the QbD work.
This provides condence to our customers
that the extractables prole as indicated
by our method is consistent over time.
This minimizes risk or variation with drugproduct leachables.
We realize that drugs take years to be de-
veloped and approved rom a regulatory
standpoint. They can then be on the market
or years. This ngerprint approach helps
provide an assurance o material consis-
tency over those extended years.
PharmaQbD:QbD requires coordination
between those who research and develop aproduct and those will ultimately manuac-
ture it. Can you share examples o how you
have achieved better integration between
key personnel throughout the development
liecycle?
FlD: Our R&D and Operations teams were
engaged globally in this program. This was
not a development and a hand-o but a co-
operative eort o both parties. Additionally,
we have instituted a global Knowledge Man-agement system to assure that inormation
is stored and shared on an ongoing basis.
PharmaQbD:What were the challenges in
building a Quality Target Product Profle
(QTPP)? What did your team learn rom the
QTPP process?
FlD: Marketing was responsible or den-
ing the QTPP. However, the biggest chal-lenge was being able to provide the spe-
cics and not assume anything. We ound
the hardest part to be dening the Criti-
cal Quality Attributes (CQA) with the R&D
unction, as the CQAs needed to be mea-
surable and specic.
PharmaQbD: What are the critical qual-
ity attributes (CQAs) or components such
as stoppers and syringe plungers, and how
were they determined?
FlD: There may be multiple CQAs deined
to achieve a target QTPP. We have these
clearly deined, but the speciics are
conidential and will only be shared spe-
ciically with customers. The CQAs were
determined through a combination o
marketing, technical, R&D, laboratory and
other experts working together, along
with customer input.
PharmaQbD:What key leanings rom the
development o the NovaPure products will
you incorporate into how you design and
manuacture syringes and other products?
FlD: We will continue to use these tech-
niques or new products that are intended
or customers and markets that will value
this approach. A component built by Qual-
ity by Design brings numerous benets to
our customers. This involves things such asin-depth process and product understand-
ing, a QTPP built around the patient and
our customer, improved transparency due
to a greater understanding and sharing o
inormation and ultimately a lower total
cost o ownership or the pharmaceutical
or biopharmaceutical company.
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The Advantage ofUnrivaled Quality...by Design
Ensuring a drug product maintains its
safety and efcacy from concept to
commercialization while reducing total
cost of ownership requires high-quality
packaging components.
West designed NovaPure components
within a Quality by Design framework.Our data-driven process provides a
deeper understanding of our product
development and manufacturing
processes. We apply this knowledge
to components that can help customers
build quality, safety and efcacy into
their drugs.
Our holistic approach encompasses
a thorough process review, from raw
materials to commercial manufacturing
to transportation of components to the
customers facility.
NovaPure serum stoppers, lyophilization
stoppers and syringe plungers areglobally available with a reduced lead
time, and are provided in optimized
packaging that helps ease the transition
through manufacturing environments.
West NovaPure
#6669
The New Definition of High-Quality Components
West and the diamond logo and NovaPure are registered trademarks of West Pharmaceutical Services, Inc., in the United States and other jurisdictions.
Copyright 2012 West Pharmaceutical Services, Inc.
Unrivaled Qualityby Design
To learn more about Wests
NovaPure technology, call your West
account manager or a Technical
Customer Support representative.
Contact West today.
North America +1 800-345-9800
Europe +49 2403 7960
Asia Pacic +65 6860 5879
www.westpharma.com
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nne rerefor more informationclick on the links below
cAN You sEEtHE REAl QbDGawayne Mahboubian-Jones
http://www.pharmamanuacturing.
com/articles/2011/068.html?page=ull
iMPlEMENtiNGQbDby Helen Winkle, FDA
http://www.da.gov/downloads/
AboutFDA/CentersOfces/CDER/
ucm103453.pd
CLICKhERE
CLICKhERE
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