GMPs for Equipment, Utilities and Facilities - Live Online Training

18-20 April 2023

Course No. 20369



Dr Jean-Denis Mallet

Dr Jean-Denis Mallet

Former Head of the Pharmaceutical Inspection Dpt. AFSSAPS

Markus Multhauf

Markus Multhauf

Consultant Pharmaceutical Engineering

Dr. Ingrid Walther

Dr. Ingrid Walther

Pharma Consulting Walther

Stephan Reuter

Stephan Reuter

Optima Pharma


This course explains how the requirements laid down in the GMP and FDA regulations can be put into technological and Engineering practice. The whole lifecycle from the design, the qualification and the maintenance of equipment is covered. The Annex 15 of the EU GMP Guide plays an important role here as well.


Technical compliance is a wide field, especially when taking into account the ICH framework which covers the whole lifecycle of pharmaceutical manufacturing.
It does not only mean to comply with regulatory guidelines but also with submissions and the technological state of the art, meaning ISO and other standards as well as accepted good practices in the pharmaceutical industry.
In this GMP course we want to focus on the main topics with regard to compliance in the technical Environment:
Technical QA aspects
There are a number of quality assurance systems which are crucial for the technical units. Most important are changes and deviations (as they also can occur in technical environment) which have or might have a direct impact on the pharmaceutical material produced. And even more important is the validation system, where the qualification of equipment, utilities and facilities has to be part of.
GMP Facility & Re-Construction
Designing an appropriate layout belongs to this part as well as understanding what the GMP requirements for the cleanrooms and for the HVAC systems are, depending on the type of manufacture. Re-Construction during on-going manufacture is supreme discipline in this field.
GMP-compliant design of equipment
A GMP-compliant design of equipment is the basis for fulfilling the technical requirements. In this respect, engineering assumes a prominent role in ensuring the safety of medicinal products. In this context, the need for material certificates is often subject to discussion.
Validation / Qualification
Not only GMP regulations but also inspectors consider qualified equipment and validated processes as the prerequisites for producing pharmaceutical quality. The identification of the Equipment that has to be qualified by means of a risk analysis is a crucial point. This field has now re-gained considerable attention as the regulations are changing: After FDA’s new guide on Validation (and process verification) also Annex 15 of the EU GMP Guide has been revised.
Routine Operation
Preventive maintenance in pharmaceutical production is an essential element of the Pharmaceutical Quality System. Systems for calibration & handling of repairs are of equal importance for maintaining the qualified state. That’s why maintenance and calibration are parts of an efficient requalification system, besides the change control and deviations systems of course.

Target Group

This course is directed at staff in pharmaceutical engineering departments, at technicians, engineers, planners as well as plant constructors and equipment suppliers who are involved in Tasks related to engineering work in a cGMP environment.

Technical Requirements

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GMPs for Equipment, Utilities and Facilities - Live Online Training

Seminar Programme as PDF

QA systems with technical relevance
Part 1:
Change Control, Technical Changes and Marketing Authorisations
  • Regulatory Requirements
  • Identification of „Changes“ - What has to be handled under Change Control?
  • CC-Workflow and pitfalls
  • Change Management in Routine Operations vs. Project work
  • Marketing Authorization - Regulatory Affairs for Engineers
Part 2:
Deviations, CAPA & Malfunctions
  • Deviations in the technical Environment
  • Documentation in logbook and higher-level Systems
  • Evaluation of technical deviations
  • When does a deviation require CAPAs?
  • Handling of Alarms
  • Correlation between changes, deviations, repairs and maintenance
  • Examples
Risk Analysis
  • Managing risks in the technical Environment
  • Project risks
  • Equipment risks
  • Product risks
  • Risk management Tools
  • Examples
Qualification, Re-Qualification & Commissioning
  • What to write in a URS & what not
  • Using risk analysis from kick-off to routine Operation
  • Handling impact and non-impact Systems
  • From URS to PQ: step by step
  • How to ensure traceability?
  • System Verification / Validation
  • Re-Qualification: How to..? And how often?
  • Examples
Materials and Surfaces
  • Which materials can be used and for what purpose? Stainless steel, plastics, polymers,…
  • How smooth have surfaces to be? Roughness and structures of cleanable surfaces
  • What are the requirements on welding?
  • Effects of corrosion, failures, and damage
GMP-compliant equipment design
  • Open and closed Systems
  • Overview on important construction details for sterile and non-sterile applications
  • Design of gaskets and problems with gaskets
  • Allowed lubricants
  • Valves
  • Pumps
  • Examples of GMP-compliant equipment
GMP Zone Concepts (sterile/non-sterile/highly potent)
  • Basic GMP requirements for materials & pharmaceuticals handling
  • Physical requirements (areas) vs Dynamic requirements (HVAC)
  • Finding the correct requirements depending on the manufacturing Operation
  • Defining an appropriate layout and air lock Concept
  • Defining personnel & material flows
  • Product vs Personnel Protection
  • Product Protection concepts, types of air flows
  • Avoiding Cross Contamination: the EMA idea
  • The future of barrier systems (Isolator and RABS)
GMP Class Requirements (HVAC and Barrier systems)
  • Some HVAC system concepts (e.g. fresh air / recirculated air)
  • Understanding the main parameters (volumes, pressure, cleanliness, etc.)
  • GMP Classification and ISO standards, and their interaction
  • The basics of air filtration and flushing air circulation
  • Particle testing depending on the cleanroom Zone
  • Microbiological monitoring in a cleanroom
  • Requirements on construction of floors, ceilings and walls
  • Classification, Qualification, Requalification of Cleanrooms
Upgrading, re-construction and renovation of  facilities
  • Required as built documentation to start
  • What to consider in re-construction projects?
  • How to protect the ongoing manufacturing operations
    • Protection of products
    • Protection of equipment, rooms and HVAC
    • Flow concepts and control of external personnel
    • Access control, pest control, cleaning
    • Documentation of protective measures
  • Examples from recent projects
Pharmaceutical Water Systems
  • Regulation Basics
  • Generation: Purified Water, WFI, Pure Steam
  • Components: working principles and hazards (Softener, EDI, RO,...)
  • Storage and Distribution concepts
  • Sanitisation principles, avoidance of Biofilms
  • Automation, Instrumentation, Trending
  • How to handle OOS in a water system
Maintenance & Calibration
  • Life-cycle model of pharmaceutical Equipment
  • How to set up and maintain a maintenance/calibration System
  • Definition and control: frequencies, activities, tolerances, acceptance criteria, etc.
  • Timing of activities
  • Documentation & labeling
  • Data integrity
Impact of the new GMP Thinking on Engineering
  • Impact of the new Annex 15
  • State of validation / qualification in the US
  • Impact of ASTM E 2500 on European Projects
  • Changes coming from ICH Q 8-10
  • How to comply with EU and US requirements in technical Projects
  • Practical examples


This course is part of the GMP Certification Programme "ECA Certified Technical Operations Manager" Learn more

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