Professional Documents
Culture Documents
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Raw Materials,
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Handling
CONTENTS
Section Page No
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1. MATERIAL STORAGE
The methodology for the storage of materials (separation and segregation) is addressed
in SOP 400.010 Supply Chain Management, which is contained in Appendix H.I.I. A
regular review of the methodology behind the storage procedures of materials is carried
out. This ensures a proper system of storage is implemented.
Materials at Schwarz Pharma Limited are stored in discrete locations depending on the
nature/status of the material. The Health & Safety Officer must be informed of all new
materials as per SOP 610.014, in order that the correct storage location for the material
may be determined based on the chemical properties of the material. Locations of
storage areas within the main facility are contained in Appendix H.1.2 Chemical
Storage, Site Map.
There are two main bulk chemical storage areas. The Nitration tank farm is located
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immediately to the west of the Plant and is approximately 208m’ in area. It holds 8
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storage tanks for solvents and each ranges in size from 15 to 30m3. The tanks are fully
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bunded and closed so that any accidental spillages or leaks are contained. The
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associated transfer pumps are located within the bunded area. The solvents are hard-
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piped via a modified pipe rack to the Nitration Plant. The over ground pipe is detailed in
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An additional storage tank farm is located at the Main Production Building (BPC) which
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holds a further 13 tanks. The nature and quantity of material is detailed in storage areas
within the main facility are contained in Appendix H.1.2 - Chemical Storage. To minimise
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air emissions, treatment/abatement equipment was installed on vessels in the BPC that
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hold substances classified as Class I under the TA Luft 1986 Organics classification
system. This equipment comprises acidic/basic scrubbers for emissions from reactors.
Raw material and packaging for use in pharmaceutical manufacturing, Work in Progress
(WIP) & all finished goods are stored in the Pharma Warehouse. The Chemical
Warehouse is used for the storage of solid raw materials, intermediates & packaging for
use in API manufacture, which require storage indoors.
The Covered drum store, Drum store has two racks and ground level storage. This area
is used for storage of the corrosive Sodium Hydroxide (pearl) & compatibles e.g.
Sodium Chloride. The Open Drum has 6 racks and a number of ground level storage
areas. It is used for storage of drummed solvents/liquid reagents & API work in
progress.
Due to the hazardous & water sensitive nature of Lithium Amide, n-Butyl Lithium &
Vilsmeier Reagent, they have a unique storage location in the ‘Lithamide’ store.
Cylinders of Gas used in processing, maintenance & laboratories are stored in a
dedicated area. There is one rail container used as temporary storage area for
recyclable fibreboard drums.
A dedicated Waste Management Area is in operation at the site. All measures have been
taken to ensure adequate storage space is provided and the area is of suitable
construction to prevent a risk of surface and groundwater pollution. All waste stored is
clearly labelled and marked. A procedure for collection, storage and disposal of waste oils
and scrap metal is employed at the site. Waste Oil control procedures have been put in
place and a dedicated waste oil storage area has been created in the drum storage area.
2. MANAGEMENT OF MATERIALS
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A tool for the procurement of chemicals, inventory management, manufacturing, release
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and shipment of products called Systems, Applications and Products for Data Processing
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management through improved chemical classification for storage and better tracking of
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SAP controls storage at two different levels, Inventory Managed (IM) and Warehouse
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Managed CJVM):
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n WM storage allows the storage in discrete ‘bins’ & the exact quantity of material in
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. IM storage shows the total quantity of material stored in a particular location but
does not display storage to bin level.
The SAP system takes into account the properties & classification of the substance to be
stored, & uses this to dictate the storage location of material. SAP will not allow the
storage of different batches of the same material in a bin nor will it allow the storage of
two different types of material in the same bin. The only exception is the open drum store,
which allow a mixing of different materials due to the availability of bin spaces. The
system will not chose to supply a material to any production process if the material is in
When QC passes the material on the SAP system it becomes available to be utilised by
production. The SAP system will only supply material to production in the absence of any
letter after the batch number selected.
Attachment
NoH.1-MainTextdoc Page2
3. MOVEMENT OF MATERIALS
Solid materials are received at the facility in either steel/fibre drums fitted with tamper
proof closures or bags and are unloaded directly in the warehouse. The materials are
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firstly subject to quarantine and following satisfactory quality control checks, then stored
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in the warehouse, until requisitioned by the production department for processing.
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Movement of solid material externally on-site is by pallet truck or fork truck. Internal
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move-ments of the material is via lifts for floor to floor transfer or charged via stainless
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Liquid materials are transported on-site in steel drums and plastic containers, similar to
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the movements of solid materials. Within processing buildings, drums are charged from
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dedicated areas. Such areas incorporate closed drains for collection and containment
purposes, which may be accessed to facilitate cleanup of any spillages.
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The movement of materials across the site is shown in Appendix H.1.6 Material Flow. All
physical movements of material and quantity will be reflected immediately on the SAP
system once the transfer orders created for movement of material to required locations
are confirmed. See SOP 400.053 Transfer of Material to Production.
4. BUND MANAGEMENT
All bunds at the Schwarz Pharma Ltd. facility, including Drum stores, Scrubbers, WWTP
and Glycol bunds, are lined. A map indicating the locations of all bund locations is
included in Appendix H.l.5. The Drum storage area has been tested for its resilience to
forklift and truck traffic. Full integrity tests of bunds takes place at a maximum frequency
of 3 years and records relating to the testing are held by the Engineering Department at
Schwarz Pharma. A copy of the most recent bunding report for the Schwarz Pharma Ltd.
facility is included in Attachment H.1.3. This also includes a report on non-compliant
bunds. A summary of the outcome of the testing is included in Appendix H.1.7.
Schwarz Pharma Ltd. has defined a process whereby containment bunds are routinely
inspected and drained of their contents in such a manner as to prevent any possibility of
Affachment
NoH-1-MainText.doc Page3
Schwarz Pharma Ltd. has implemented a programme for the provision of satisfactory
containment at the facility. The main aims of the programme included the bunding of tank
and drum storage areas. A preliminary risk assessment of material storage at the facility
identified those areas requiring primary action and those storage areas requiring
impervious surfaces to materials stored therein. In total, 29 bunds were identified for the
purposes of this programme (3 bunds located at Bay 130 are now no longer in use and
are therefore not included within the 29 bunds).
All materials drained from bunds are discharged directly to the drainage network, which
brings the effluent to the wastewater treatment plant. The only exception to this rule is the
discharge of nitration bunds. The contents of the nitration plant bunds are normally
discharged to surface water and are only discharged to the wastewater treatment plant if
contaminated. Before discharging liquid from the tank farm bunds, the bunds are checked
for pH to ensure acidity is not a concern. Before discharging from the Mother Liquor
Bunds, the liquid must be checked to ensure it does not contain solids or odour.
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1.0 PURPOSE
To outline the procedure for the storage of all materials (including Packing Materials) to ensure the
proper separation and segregation of chemicals at SCHWARZ PHARMA Limited.
2.0 RESPONSIBILITY
* 2.1 It is the responsibility of the Supply Chain Manager to ensure that the concerned individuals
are familiarised with this SOP in accordance with SOP No. 103.001.
2.2 It is the responsibility of the Materials Technologist & the Warehouse Team Facilitator to
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ensure that material is stored in a safe and controlled maturer.
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2.3 It is the responsibility of the Materials Technologist in consultation with the Environmental
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and Health Safety Department to provide guidance in the safe storage of materials and that the
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3.0 APPROWL
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This SOP and any future changes must be approved by the Supply Chain Manager, the API Manager,
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the Health and Safety Offtcer, Pharma Manager, and the Head of QA and Support Services.
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4.0 SCOPE
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This SOP is in effect in the Supply Chain Management and Manufacturing Departments.
5.0 PROCEDURE
l 5.1 There are several warehouse storage locations & types in SCHWARZ PHARMA Limited and
these are listed in Attachment I and maps showing all the Storage areas
(Attachments III-VI).
5.2 For safety/regulatory purposes, materials at SCHWARZ PHARMA Limited are stored in
discrete locations depending on the nature/status of the material. The Health & Safety Officer
must be informed of all new materials as per SOP 610.014, in order that the correct storage
location for the material may be determined based on the chemical properties of the material.
Written By: Approved By: Approved By: Approved By: Approved By Approved By:
Page 2 of 7
SUPPLY CHAIN MANAGEMENT PROCEDURE SOP
Effective Date:
Title: STORAGE OF MATERIALS 400.010 Revision No: 20 Date: 10.02.04
Prev Rev No: 19 Dated: 02.10.02
5.3 Under no circumstances must drums of flammable liquids be stacked more than two pallets
high. The maximum stack height for fibreboard drums is three pallets high
Note: Material locations and contents areprinted once on a weekly basis and the copy is
supplied to the Security Oj?cer every Thursday.
5.4 A computerised system; SAP is used to control the storage and selection of materials
throughout all storage locations at SCHWARZ PHARMA Limited.
5.5 SAP controls storage at two different levels, Inventory Managed (IM) and Warehouse
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Managed (WM) - See Attachment I.
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5.5.1 WM storage allows the storage in discrete ‘bins’ & the exact quantity of material
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5.5.2 IM storage shows the total quantity of material stored in a particular location but
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5.6 The SAP system takes into account the properties & classification of the substance to be
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stored, & uses this to dictate the storage location of material (Attachment II).
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5.7 SAP will not allow the storage of different batches of the same material in a bin nor will it
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allow the storage of two different types of material in the same bin. The only exception is
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the open drum store, which allow a mixing of different materials due to the availability of
bin spaces.
5.8 The system will not chose to supply a material to any production process if the material is
in
Quarantine (represented as letter Q on SAP)
Blocked stock (represented as letter S on SAP).
5.9 When QC passes the material on the SAP system it becomes available to be consumed by
production. The SAP system will only supply material to production in the absence of any
letter after the batch number selected.
Note: All physical movements of material and quantity will be reflected immediately on the
SAP system once the transfer orders createdfor movement of material to required
locations are con$rmed See SOP 400.053 Transfer of Material to Production
5.10.1 TankFarm
5.10.1.1 Bulk solvents/reagents are stored in dedicated tanks in the tank farms.
There are two distinct tank farms at; SCHWARZ PHARMA Limited
Main tank farm (SOP 400.011) & Nitrates Tank farm (SOP 400.052)
both of which are treated as IM storage location 0061 in SAP.
5.10.1.2 Nitric acid for Bay130 is stored in a bulk tank (SOP 400.014) under
IM storage location; 0130.
5.10.1.3 Tank 14 in the main tank farm is used for the storage of bulk waste
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solvent for disposal and is assigned a separate storage in SAP; IM
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location 0014.
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Pharma Work in Progress (WIP) & all finished goods are stored in the
Pharma Warehouse (WM 050).
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5.10.3.2 Capsule Shells, Finished Product Capsules and Tablets are not stored on the
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API manufacture, which require storage indoors (WM 00 1).
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5.10.4.2 The storage is on racking, A to M, primarily for the storage of Class
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5.10.4.6 Plastic drums are stored over the Office in the Chemical Warehouse.
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5.10.6.3 The Open Drum store (WM 003) has 6 racks & a number of ground
level storage areas (A to L) & is used for storage of Drummed
solvents/liquid reagents & API work in progress (Rack B).
5.10.6.4 Rejected/ Waste material is stored on Racks A & F in this area in
location WM 005.
5.10.6.5 Oil, Sodium Hypochlorite & Bromine have dedicated bunded storage
areas within this location.
5.10.6.6 An additional waste management area is denoted by location WM
007.
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5.10.7 Production Areas
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Material which is required for manufacturing is transferred to the
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5.10.7.2
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5.10.10.2 Storage is provided for both API & Pharmaceutical materials.
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API liquid raw materials are stored in racks in the open store (Racks
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5.10.10.4 Racks A & B in the B130 warehouse are used as a Pharma production
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supply area & for the short term staging of Pharma finished products
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5.10.10.5 Racks C & D are used as an API production supply area & for the
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48hrs).
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5.10.10.6 Packaging materials (Liners, fibreboard drums & 200L plastic drums)
are also stored in location 0130.
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5.12 Documentation
Attachment I: List of Warehouse Locations (IM & WM locations)
Attachment II: List of Classification.
Attachment III: Map of the Drum Store areas of the Main Plant.
Attachment IF Map of Pharma Warehouse Locations.
Attachment k Map of Chemical Warehouse Location.
Attachment Y7; Map of Bay 130 Store.
Attachment WI: Site Map.
Page 7 of 7
SUPPLY CHAIN MANAGEMENT PROCEDURE SOP
Effective Date:
Title: STORAGE OF MATERIALS 400.010 Revision No: 20 Date: 10.02.04
Prev Rev No: 19 Dated: 02.10.02
6.0 FtEWISION
This SOP is reviewed annually according to SOP 100.007. Any necessary changes will be
documented in a new revision of this SOP
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Returns area Pharma Warehouse
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Pharma Warehouse
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050 904
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- Chemical Warehouse Chemical Warehouse safe
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008
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Open Drum store Covered Drum Waste material rack Open Backyard storage
003 store 005 007
BPC Production Supply Area (PSA) Nitration PSA Pharma Dispensing Pharma Effluent Supply
020 060 PSA Pellitising PSA area
051 052 054
BPC Work in Progress Area (WIP) Nitration WIP area Pharma WIP area
021 031 055
Rail Containers
011
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C3LIQ 3 Flammable Liquids
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i A B E C DGJHKILI 003 i
DRUMSTORE 2
AT
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DRUMSTORE 1
B
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SOP Page 1 of 1
SUPPLY CHAIN MANAGEMENT PROCEDURE
ATTACHMENT IV 400.010
Effective Date:
Revision No: 20 Date: 10.02.04
Title: MAP OF PHARMA WAREHOUSE Prev Rev No: 19 Dated: 02.10.02
LOCATIONS
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WAREHOUSE
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SOP Page 1 of 1
SUPPLY CHAIN MANAGEMENT PROCEDURE
ATTACHMENT V 400.010
Effective Date:
Revision No: 20 Date: 10.02.04
Title: MAP OF CHEMICAL WAREHOUSE Prev Rev No: 19 Dated: 02.10.02
LOCATIONS
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Last Modified
Drawing No. O%%%+,
(1 pi-k--j
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Production storage
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To include Section 5.13
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To include the maps revised and
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updated on 17.08.00
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14 GT 17.10.00
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.,:3: . ,.’
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l To update list of signatories and
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department changes.
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storage 006
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Update signatories
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Copvc.
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I have destroyed (returned in the case of BMI’s) the superceded revision of the SOP.
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Signed: Department:
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Date:
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Appendix H.l.2
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Chemical Storage,
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Site Map
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-
RAW
WASTE
M,mR!AL IN/OUT
- ,NTERh,EDli\TE / PiiODUCT
L: UQUID WASTE
9: SOLID WSTE
,_._..___-.-- - ---
,’ BOUNDARY
,/”
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7 25/5/04 CC 04/189,Monitaring F
5 26/T/02 Updoted
4 13/5/02 Updated