Avoiding non-Compliance in Packaging Operations - Live Online

Avoiding non-Compliance in Packaging Operations - Live Online

Course No 19039

This course is part of the GMP Certification Programme "ECA Certified Packaging Manager". Learn more.

Note: All times mentioned are CET.


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David Abraham, QRS & Project Leader in the development of PS 9000:2016, UK
Maren Göpfert, Boehringer Ingelheim Pharma, Germany
Jérémy Jacquart, PHARMAPLAN, France
Dr Franz Schönfeld,  GMP Inspector, Germany


This GMP Live Online Training Course aims at easily explaining the GMP requirements for packaging of medicinal products.

This includes requirements for premises and equipment but also for QA operations like documentation, line clearance, validation etc.


Packaging of medicinal products, blistering as well as cartoning for example, plays a crucial role in the quality and safety of a medicine. Deficiencies of primary packaging may alter the efficacy or stability of a product; failures in secondary packaging may do harm to patients even worse when products or the folding boxes are mixed up. Therefore, packaging is defined as (the last) pharmaceutical manufacturing step and one of the most critical ones. It is not surprising that the biggest part of recalls is caused by failures during packaging. The FDA reported that more than 30% of recalls of tablet products during the last 5 years were caused by label mix-ups, incorrect packaging or incorrect products insert. On the other hand, despite the high criticality of the packaging process, the packaging plants are required to cut the costs and raise their Efficiency.

Another challenge for the packaging units is the new EU Directive, requiring safety features and authentication measures in order to raise the hurdle for drug counterfeiters. As a consequence of the “COMMISSION DELEGATED REGULATION (EU) 2016/161”, the rules apply from 9th of February 2019 onwards except for some member states with an existing Verification System. Packaging lines have to be equipped with systems for printing and reading two dimensional codes (2D-Codes) and these systems have to be linked to the materials management system. Companies already shipping serialized products have been reporting from technical hurdles which should not be underestimated. Most companies without experience in this field will need external help. But technical expertise could become rare in the near future.

There are numerous requirements which have to be fulfilled in the packaging plant. During this GMP Live Online Training we will focus on:
  • Compliance & QA requirements
    • QA Systems
    • Hygiene and Cleaning
    • Qualification / Validation
  • Technological aspects
    • Facility and Zone Concepts
    • Design of packaging equipment
  • Packaging materials
    • Handling, storage and mix-ups
    • Suppliers
  • Special topics:
    • Serialisation & Authentication
    • Highly Potent Products

Target Group

Staff from QA and production engaged in packaging operations is the target group of this course as well as suppliers for equipment and packaging material used for packaging of medicinal products.

Technical Requirements

For our Live Online Training Courses and Webinars, we use Cisco WebEx, one of the leading suppliers of online meetings. At https://www.webex.com/test-meeting.html you can check if your system meets the necessary requirements for the participation at a WebEx meeting and at the same time install the necessary plug-in. Please just enter your name and email address for the test. If the installation is not possible because of your rights for the computer system, please contact your IT department. WebEx is a standard nowadays and the necessary installation is fast and easy.


Note: Provisional timetable, the actual schedule may vary depending on the situation.
Programme Day 1
09.00 - 09.15 h Welcome & Introduction
09.15 - 10.15 h
GMPs and QA Oversight for Packaging Operations
  • GMP requirements in the packaging unit
  • Important Guidelines and standards
  • QA Systems relevant for packaging operations
  • Frequent inspection findings
10.15 - 10.20 h Short Break
10.20 - 11.30 h
General GMP requirements for Packaging Operations / Key Compliance Challenges for Packaging Operations
  • Handling and storage of packaging materials
  • Testing
  • Stability issues
  • Material storage, returned goods, quarantine
  • Line Clearance
  • Documentation practice
  • Practical GMP aspects
  • Good and bad practice
11.30 - 11.45 h Break
11.45 - 12.30 h
Quality and Compliance systems in the Packaging Plant
  • Hygiene and Zone Concepts
  • Material flow
  • Line clearance procedure
  • IPCs in the packaging process
  • Documentation and control
  • Handling of variable printing data
12.30 - 13.00 h
Q&A Session 1
13.00 - 14.00 h Break
14.00 - 15.00 h
Packaging of Highly Potent Products / Q&A Dynamic Session on Packaging (Tips & Problems)
  • Cross Contamination – how to avoid it:
    • 1 – dedicated vs multi product facility
    • 2 – production planning
    • 3 – cleaning procedures
    • 4 – people movement
15.30 - 15.30 h
Secondary Packaging (Interactive Session)
15.30 - 15.45 h Break
15.45 - 16.30 h
The Application of GxP in Packaging Supply
  • Relevant ISO standards
  • Introduction to British “GMP for Packaging Materials”: PS 9000:2016
16.30 - 17.00 h
Q&A Session 2
Programme Day 2
09.00 - 10.00 h
Packaging Facilities & Premises / GMP Design Aspects for Packaging Lines
  • Requirements for the technical building equipment
  • Zone Concepts for primary and secondary packaging
  • Air-Lock concepts
  • Hygiene
  • HVAC
  • Design criteria for blister machines, cartoners, labelers
  • Differences to aseptic filling / packaging
  • What is critical?
  • What to write in an URS?
10.00 - 10.45 h
Reducing Risk through Supplier Auditing
  • How much GMP must a supplier have?
  • Practical audit aspects: what to examine?
  • Qualification of suppliers
10.45 - 11.00 h
Qualification and Validation
  • Equipment qualification
  • Process validation
  • Critical issues which have to be tested
  • How to test?
11.45 - 12.15 h
Q&A Session 3
12.15 - 13.15 h Break
13.15 - 14.00 h
Serialization and Aggregation – How we implemented, what worked and what didn’t
  • Challenges in the implementation phase
  • Equipment qualification/ process validation
  • Packaging material management
  • Impact on the Supply Chain
  • Handling of Failures / Deviations / Complaints
14.00 - 15.00 h
How to minimize Risk in Sterile Packaging
  • What can go wrong in sterile packaging?
  • How to minimize these incidents applying QRM principles.
  • Aseptic filling and terminal sterilization:
    • Microbiological quality of the primary packaging components
    • Media Fill
    • Container Closure Integrity (CCI)
15.00 - 15.05 h Short Break
15.05 - 15.30 h
Q&A Session 4

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