Validation Protocol-Fermentation Vessel Sterilization

Validation Protocol-Fermentation Vessel Sterilization
Subject: Validation Protocol for sterilization of BioFlow 110 3 Liter Bioreactor. Document #: VP001 Revison:0.0 Effective Date: January 1, 2006 Page 1 of 6	Prepared By: T. Burkett_____________________ Name / Signature / Date Reviewed By:______________________ Name / Signature / Date Approved By:______________________ Name / Signature / Date

1. Scope: This document covers validation of the fermentation vessel sterilization process as described in SOP 004 –Preparation of BioFlow 110 3 liter fermentation vessel. Validation of the bioreactor sterilization procedure is conducted in order to provide documented evidence that the process described in SOP P004 will effectively sterilize growth media contained in the New Brunswick Scientific BioFlow 110 3 liter fermentation vessel and kill any microorganisms inadvertently introduced into the fermentation vessel during the preparation of media and the vessel.

2. Definitions:

2.1 NBS – New Brunswick Scientific

2.2 CFU -Colony Forming Units

2.3 CFU/ml – Clolony Forming Units per milliliter

2.3 rGFP – Recombinant Green Fluorescent Protein

2.4 D.I. H₂O – Deionized water

5. LB – Luria Bertani media

2.6 ml(s) – Milliliter(s) (10^-3 Liters)

2.7 O.D.₆₀₀ – Optical Density at 600 nanometers

2.8 μl – microliter (10^-6 Liters )

2.9 Bioreactor / fermentation vessel are used interchangeably through-out this protocol.

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The Northeast Biomanufacturing Center & Collaborative

Validation Plan-Fermentation Vessel Sterilization

Subject: Validation Protocol for sterilization of BioFlow 110 3 Liter Bioreactor. Document #: VP001 Revison:0.0 Effective Date: January 1, 2006 Page 2 of 6

3. References:

1. Guide to Operations: BioFlow 110 Modular Benchtop Fermentor Manual # M1273 0054 Revision E
2. Guide to Operations: AMSCO Eagle Series Autoclave Model 3011 Revision 4.1
3. SOP P001 - Cleaning of NBS Bioflow 110 BioFlow 110 Modular Benchtop Fermentor 3 Liter vessel.
4. SOP P004 –Preparation of NEB BioFlow 110 Modular Benchtop Fermentor 3 Liter vessel.
5. SOP P005 – Collection of In-process samples from NEB BioFlow 110 Modular Benchtop Fermentor 3 Liter vessel.
6. SOP Q001 – Determination of the number of viable bacterial cells through serial dilution and growth on Luria-Bertani media.
7. SOP Q002 - Gram Staining.
8. SOP P006 – Preparation of Luria - Bertani liquid media.
9. SOP P008 – Determination of the Optical Density of a bacterial culture

4. Reagents:

1. 70% Isopropyl alcohol
2. Sample collection vials
3. LB liquid media
4. Bacillus subtilus culture

4.5 Culture tubes, inoculating loops, bunsen burners.

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The Northeast Biomanufacturing Center & Collaborative

Validation Plan-Fermentation Vessel Sterilization

Subject: Validation Protocol for sterilization of BioFlow 110 3 Liter Bioreactor. Document #: VP001 Revison:0.0 Effective Date: January 1, 2006 Page 3 of 6

5. Responsibility:

5.1 It is the responsibility of all personnel validating the performance of the equipment covered by this validation plan to read and understand the validation plan.

5.2 It is the responsibility of the Quality Control Laboratory to perform the viable cell counts on pre and post autoclaved material described in this validation plan.

5.3 It is the responsibility of the validation department to supervise the described validation exercises in accordance with the validation schedule, in response to replacement or modification to autoclaves used for the purpose of sterilizing fermentation vessels, or, in response to modification or replacement of SOP P002, P003, or P004.

5.4 It is the responsibility of the Production Department to perform the described validation exercise and to deliver samples to the Quality Control Department for analysis.

5.5 The Quality Assurance Department will review all validation data generated in response to this validation plan and will have final sign-off on all validation certification.

6. Hazard Communication:

6.1 Fermentation Vessels, if not properly vented, may build up sufficient pressure during the autoclave process to explode. All personnel should wear appropriate safety clothing when removing fermentation vessels from the autoclave.

6.2 Autoclaved liquids may boil over and leak from the fermentation vessel. All personnel should wear appropriate safety clothing when removing fermentation vessels from the autoclave.

7. Attachments:

7.1 Validation Data Sheet

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The Northeast Biomanufacturing Center & Collaborative

Validation Plan-Fermentation Vessel Sterilization

Subject: Validation Protocol for sterilization of BioFlow 110 3 Liter Bioreactor. Document #: VP001 Revison:0.0 Effective Date: January 1, 2006 Page 4 of 6

8. Procedures:

8.1 Growth of Bacillus subtillus

8.1.1 Assemble materials necessary for the inoculation of liquid cultures (inoculating loop, Bunsen burner, culture tube with liquid media, shaking water bath at 37^oC.)

8.1.2 Obtain a frozen vial of Baccilus subtilus from the -80 freezer.

8.1.3 Record the lot number of the Baccilus subtilus cells.

8.1.4 Thaw the frozen vial on ice for 10 – 20 minutes.

8.1.5 Inoculate 2 culture tubes, each containing 10 mls of LB media, with 100 μl of thawed B. subtilus cells for each culture tube.

8.1.6 Place the culture tube in the shaking water bath set at 37⁰C.

8.1.7 Grow the cells at 37⁰C overnight (minimum of 12 hours).

8.1.8 Using the overnight liquid culture, inoculate a 500 ml baffled cultured flask containing 100 mls of sterile LB media with 10 mls of the overnight culture material.

8.1.9 Place the inoculated 500 ml baffled culture flask in a 37⁰C shaking

water bath.

8.1.10 Determine the OD₆₀₀ of the culture as described in SOP P008.

8.1.11 Grow the culture until an O.D.₆₀₀ of between 0.5 – 0.75 is reached.

8.1.12 Pool the two 50 ml cultures into 1 baffled shaking flask.

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The Northeast Biomanufacturing Center & Collaborative

Validation Plan-Fermentation Vessel Sterilization

Subject: Validation Protocol for sterilization of BioFlow 110 3 Liter Bioreactor. Document #: VP001 Revison:0.0 Effective Date: January 1, 2006 Page 5 of 6

2. Preparation of Bioreactor

1. Prepare the NEB BioFlow 110 3 Liter vessel as described in SOP P002.

2. Prepare 2 Liters of LB liquid media as described in SOP P006.

3. Add the LB Liquid media to the fermentation vessel.

4. Collect a 15 ml sample from the autoclave as described in SOP P005. Label this sample “preinoculation” with the date and time and collectors initials. Store at 4⁰C until delivered to QC laboratory.

5. Inoculate the fermentation vessel with 50 mls of culture obtained from step 8.1.12

6. Close the fermentation vessel and agitate for 10 minutes at 500 rpm.

7. Collect a 15 ml sample from the autoclave as described in SOP P005. Label this sample “postinoculation” with the date and time and collectors initials. Store at 4⁰C until delivered to QC laboratory.

3. Autoclave Bioreactor according to SOP

1. Remove fermentation vessel from autoclave and allow to cool to room temperature inside the Biological Safety cabinet.

2. Collect a 15 ml sample from the autoclaved fermentation vessel as described in SOP P005. Label this sample “post autoclave” with the date and time and collectors initials. Store at 4⁰C until delivered to QC laboratory.

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The Northeast Biomanufacturing Center & Collaborative

Validation Plan-Fermentation Vessel Sterilization

Subject: Validation Protocol for sterilization of BioFlow 110 3 Liter Bioreactor. Document #: VP001 Revison:0.0 Effective Date: January 1, 2006 Page 6 of 6

9. Acceptance Criteria

9. 1 All samples shall be delivered to the QC department on ice and the viable cell count shall be initiated by the QC department within 30 minutes of being taken from the fermentation vessel/bioreactor.

9.2 Record the results of the viable cell count performed by the QC laboratory for the samples collected and labeled pre-inoculation, post-inoculation, and post-autoclaving in the chart below.

Vessel number	Autoclave # and cycle	Pre-inoculation viable cell count	post-inoculation viable cell count	post-autoclaving viable cell count	Log reduction in viable cell count

9.3 Calculate the log reduction in viable cells between the post inoculation sample and the post autoclaving sample.

9.4 Acceptance criteria for this protocol is a 9 log reduction in viable cell count between the post inoculation viable cell count and the post autoclaving viable cell count.

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