Pharmaceutical Facility Design. Learn ONLINE the Systems that Underpin Aseptic/Sterile Processing

An injection bypasses all of your body’s natural defences. So how do you make sure that the cleanrooms used in the manufacture of sterile medicines are absolutely safe? How do you make sure the water, steam and air used are pure? In this practical course, you will learn all this and more. Core content developed in consultation with the industry including Pfizer and MSD.

  • Learn the air, water and steam systems that underpin aseptic/sterile processing

  • Conduct site master planning and cleanrooom design

  • Complete course from anywhere online in 13 weeks

  • Application Deadline: Wednesday 25th May
  • Approx. 155 hours to complete
  • Study Online part-time 12hrs/week for 13 weeks or choose a faster/slower schedule
  • Dedicated course leader who’ll check your progress at the end of every week and follow up with you to help you finish the course
  • Join 1920 Learners
Pharmaceutical Facility Design Course
Apply NOW to Learn the Systems that Underpin Aseptic/Sterile Processing

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Pharmaceutical Facility Design. Learn ONLINE the Systems that Underpin Aseptic/Sterile Processing

An injection bypasses all of your body’s natural defences. So how do you make sure that the cleanrooms used in the manufacture of sterile medicines are absolutely safe? How do you make sure the water, steam and air used are pure? In this practical course, you will learn all this and more. Core content developed in consultation with the industry including Pfizer and MSD.

Conversion Course into Pharma

  • Learn the air, water and steam systems that underpin aseptic/sterile processing

  • Conduct site master planning and cleanrooom design

  • Complete course from anywhere online in 13 weeks

  • Application Deadline: Wednesday 25th May

  • Approx. 155 hours to complete
  • Study Online part-time 12hrs/week for 13 weeks or choose a faster/slower schedule
  • Dedicated course leader who’ll check your progress at the end of every week and follow up with you to help you finish the course
  • Join 1920 Learners

Our learners work for the world’s biggest pharma and medical device companies

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AstraZenega Logo

Novartis Logo

GSK Logo

Lilly Logo

Abbott Logo

MSD Logo

Boston Scientific Logo

Medtronic Logo

Takeda Logo

Abbvie Logo

J&J Logo

See Course Price

Apply NOW to Learn the Systems that Underpin Aseptic/Sterile Processing

Try Us Risk-FREE for 7 Days 100% Money Back Guarantee.

Our learners work for the world’s biggest pharma and medical device companies

Pfizer Logo

AstraZenega Logo

Novartis Logo

Lilly Logo

Roche Logo

Amgen Logo

Sanofi Logo

GSK Logo

2

This Course is For You If;

  • You work in or are responsible for making sure the cleanroom and utilities are sterile and safe.

  • You are responsible for planning the personnel and material flows and pressure profiles to prevent cross-contamination in sterile manufacturing environments.

  • You need an in-depth program on how the systems that underpin aseptic/sterile processing are designed and run.

And..

  • You want end-of-week progress checks and follow by us to MAKE SURE you finish the course.

  • Delivered Online you can keep working and still study without wasting your time or money or training budget on hotel or travel junkets.

2

q

Enroll in this course to learn…

  • Key manufacturing technologies  – such as organic chemical synthesis, biopharmaceutical manufacturing, tablet manufacturing and aseptic & sterile manufacturing
  • Purified water generation – storage and distribution that underpin aseptic/sterile processing
  • Clean steam – water for injection, storage and distribution that underpin aseptic/sterile processing.
  • Instrumentation process control design  – for the generation and distribution of clean utility systems.
  • Cleanroom layout design – layout and classification along with the environmental controls pressure profiles
  • Aseptic processing – lyophilization and how vials are filled in an aseptic environment
  • Quality systems –  for cleanrooms for both EMA and FDA guidance on aseptic processing.

You’ll produce a number of deliverables throughout the program including…

  • Complete 8-question booklets (one for every week’s worth of content) which will summarise what you have learnt for the week and ensure you retain and understand the information.
  • Complete an end of module assignment to include the following:
    • Sketch and label process flow diagrams illustrating typical biopharmaceutical unit operations for the sequential manufacture of both drug substances and drug products.
    • Describe process support and utility systems encountered on a typical biopharmaceutical facility
    • Sketch and describe the configuration of a hypothetical cleanroom environment for aseptic processing (e.g. for vial filling operations).
    • Describe the similarities and differences between pharmacopoeia grade purified water (PUW) and water for injection (WFI).

And take the following skills and knowledge back to work…

  • You’ll have a strong foundation in how safe medicines and medical devices are made in a GMP regulated manufacturing environment.
  • You’ll understand the air, clean water and steam systems that underpin aseptic/sterile processing.
  • You’ll understand cleanroom layout design, layout and classification and the environmental controls pressure profiles
  • You’ll have the technical knowledge and understanding of the quality culture necessary to work in this environment

.

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Entry Requirements

  • You have worked in a GMP Regulated Pharmaceutical or Medical Device manufacturing environment.

.

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Hear From People Who’ve Taken This Course
Pharmaceutical Facility Design

John Ryan

“The course content material is concise and interesting”

“The professionalism and passion of the lecturers comes across in the tutorials which gives the student confidence and encouragement to keep on top of the course. The course content material is concise and interesting. The timing of the release of the lessons is perfect, the student moves at a comfortable pace, one step at a time.”

Pharmaceutical Facility Design

Ronan Balfe

“I would have no hesitation in recommending these courses”

“Studying online gives you the time to do the course in your own time yet with assignment deadlines this made you disciplined to meet the deadlines set. I would have no hesitation in recommending these courses to anyone wishing to gain an education in the pharmaceutical sector.”

Pharmaceutical Facility Design

Edel Harkins

“Highly recommended to anyone who has been out of the industry for a period of time”

“I would highly recommend anyone in my situation who has been out of the industry for a period of time to do these courses. They have contributed to my new found confidence in my existing and new qualifications, my improved interview skills and my new job!”

Pharmaceutical Facility Design

Noel O’Brien

“The quality of the course content was excellent and very substantial and covered all aspects associated within the Pharmaceutical, Bio-Pharmaceutical and Medical Device industries. Information that I feel could and would be very much a requirement for the type of work I would be seeking, within such companies.”

Pharmaceutical Facility Design

Anne Reilly

“Very important to do a course if you have been absent from workplace for a relatively long period. It just gives you the confidence to do interviews etc.”

Pharmaceutical Facility Design

Louise McManus

“Excellent course, well set out.”

Andy Wnuk, MSc (Eng) MIEI

“Along with the technical training in I would rate the course 10 out 10 and would highly recommend to others, very interesting, informative and very well presented. Relevant totally to my needs and expectations.”

David O’Shea, March 2012

“I found this course very beneficial and I am delighted that, even at early stages in the course, it has already provided me with the opportunity to secure a position within the pharmaceutical industry.”

Denis Hegarty, May 2012

“I found the course was run very professionally, The course notes and videos supplied were excellent, the notes tied in very efficiently and accurately with the videos. Dr Joe Brady’s presentation on the videos and his expertise and help at the webinars was outstanding. I found it very easy to continue studying even though I found employment two months into the course. I would highly recommend this course to anyone hoping to further their education in this field.”

Tan Sear Enyu, Venture Corporation Limited, SA

“The lecturers have vast knowledge to share and are technical specialists within the Life Sciences Industry…there was a lot of encouragement and team exchange of experience to bring in for class work and assignment participation.”

Your 13-Week Class Schedule

This module was developed in consultation with the pharma industry including Pfizer and MSD.

Week 1 – Controlling Air Quality and Clean Utilities Part 1

  • 1.1 Manufacturing Logistics Calculations
    In this lesson, we learn how to determine the size and capacity of primary processing equipment based on patient dosage requirements and the number of potential patients.
  • 1.2 Process Flow Diagram (PFD) 
  • 1.3 Controlling Air Quality In this lesson, we take our first look at an air handling unit (AHU) and describe its functions.
  • 1.4 Heating, Ventilation, and Air Conditioning (HVAC) Systems In this lesson, we take a look at an overall heating and ventilation control (HVAC) system and explain its primary attributes.
  • 1.5 Basic Biopharmaceutical Unit Operations
    1-5-1 In this presentation we look at the basic biopharmaceutical unit operations that make up a typical drug substance manufacturing operation.
    1-5-2 In this presentation we look at the basic biopharmaceutical unit operations that make up a typical drug product formulation/fill-finish and packaging/labelling manufacturing operation.
  • 1.6 Pharmacopeia Grade Waters
  • 1.7 Process Support and Utilities
    In this lesson, we take a look at the clean utilities requirements for a biopharmaceutical drug substance manufacturing process.

  • 2.1 Introduction to ISO 9001:2008 and 2015
    This lesson is about the key requirements of a quality management system.
  • 2.2 Typical GMP list for drug substance
    This lesson explores the content of ICH Q7 “Good Manufacturing Practice Guide for Active Pharmaceutical Ingredients”.
  • 2.3 Operational Activities
    In this lesson, we take a look at how to maintain a critical computerized system in a state of operational control using standard procedures.
  • 2.4 GMP for Personnel
  • 2.5 Quality Systems Approach to Pharmaceutical cGMP Regulations – The Quality Systems Mode
    In this lesson, we describe a quality system model in accordance with management responsibilities, resources, manufacturing operations and evaluation activities.
  • 2.6 Maintenance: Good and Best Practices
    In this lesson, we describe basic and good practices associated with maintenance in a regulated environment.

  • 3.1 Project Lifecycle for New and Modified Facilities
    In this lesson, we describe the typical phases of a project lifecycle: conceptual design, tender contract analysis, basic engineering, detailed design, and project realization.
  • 3.2 Plant Layout
    In this lesson, we explore the vertical distribution of process equipment for a bulk process building, the horizontal layout for a bulk process building, and an entire site layout for an integrated biopharmaceutical manufacturing site.
  • 3.3 Zoned Air-Conditioning Systems
    In this lesson, we look at a practical example where a HVAC system can be dynamically operated to control the temperature of a room (space).
  • 3.4 Isolator Technology
    In this lesson, we explain the principles behind the use of ‘isolators’ and Restricted Access Barrier Systems (RABs) for critical ‘open processing’ operation.
  • 3.5 Cell Breakage
    In this lesson, we describe a mechanism for bacterial cell disruption for the recovery of intracellular products.

  • 4.1 Purified Water (PUW) Generation, Storage and Distribution
    In these lessons, we look at methodologies to generate, store and distribute pharmacopeia grade purified water (PUW).
  • 4.2 Clean Room and Clean Air Device monitoring 
  • 4.3 Good Engineering Practices Procedures
    In this lesson, we will develop an understanding of good engineering practices, and learn about some various organizations that produce them.
  • 4.4 GMPs for Buildings and Facilities 
  • 4.5 Quality Systems Approach to cGMP Regulations – Management Responsibilities
    In this lesson, we outline management’s role in the design, implementation, and management of the quality system.
  • 4.6 Maintenance Program
    In this lesson, we describe the key aspects of a typical maintenance program.

  • 5.1 Conceptual Design – Part-1
    In this lesson, we begin to explore a quantified effort in how to size, shape, program, and cost an investment.
  • 5.2 HVAC Requirements for Non-Sterile API Manufacturing
    In this lesson, we look at how to use airflow direction as a means of a containment barrier between operational areas in a non-sterile multi-product active pharmaceutical ingredient (API) manufacturing facility.
  • 5.3 Plant Automation
    This lesson is an introduction to conventional process control using one-way digital and analogue signals.
  • 5.4 Plant Steam
    In this lesson, we describe a process for generating and distributing plant steam to various processes within a manufacturing facility, and also describe how to manage any resultant condensate.
  • 5.5 Clean Steam Generators
    The objective of this lesson is to demonstrate how we produce clean steam using ‘Single-Effect Distillation’ ‘Multiple-Effect Distillation. 
  • 5.6 Steam Sterilization in Place
    In these lessons, we look at the mechanism behind sterilization of process equipment using saturated steam.
  • 5.7 GMPs for Process Equipment 
  • 5.8 Quality Systems – Resources
    In this lesson, we describe what resources need to be allocated for a quality system and operational activities.

  • 6.1 Conceptual Design – Part-2
    This lesson describes what influences the layout of a facility in terms of: Layers, Preliminary Layout, Process Layouts, Media and Buffer Preparation, Clean Utilities and CIP, Access Corridors, Warehouse / Material Movements, Personnel Movements, Decisions on Height, Air Handling, General Utilities, Electrical, Controls & Automation, Finishes, Structural / Civil, Cost Estimate, and Schedule.
  • 6.2 Air Flow Patterns 
    In these lessons, we look at laminar air-flow patterns in the context of filling open vessels aseptically, and at the configuration and operation of both a laminar flow booth and a laminar flow cabinet typically found in the biopharmaceutical industry.
  • 6.3 Cleanroom Layout 
    In this lesson, we take a high-level look at a common cleanroom configuration and discuss items such as airflow direction, filter arrangements, cleanroom garments, and personnel and material flows. Another objective of this lesson is to also gain an understanding of personnel and material flows in a controlled airflow environment designed to contain high potency chemicals. 
  • 6.4 Filter Ratings
    In these lessons, we look at the particle retention efficiencies of air filters of various grades rated in accordance with European normalisation standards EN779 and EN1822. We also look at the particle arrestance efficiency of air filters of various grades rated in accordance with the ASHRAE standard 52-2 ‘Minimum Efficiency Reporting Value (MERV Rating)’.
  • 6.5 Logic Gates Functions and PLC 
  • 6.6 WFI Storage and Distribution
    In this lesson, we take a look at a process for the storage and distribution of pharmacopeia grade water for injection (WFI) and how to maintain its specification.
  • 6.7 Good Engineering Practices Procedures
  • 6.8 Quality systems Approach- Manufacturing
    In this lesson we describe Manufacturing’s responsibilities for (a) designing, developing, and documenting product and processes, (b) examining inputs, (c) performing and monitoring operations, and (d) addressing nonconformities.
  • 6.9 Maintenance- Work Executions
    In this lesson we describe the following Maintenance tasks and activities: (a) work request, (b) work order management, (c) information requirements for work orders, and (d) performance measurement.

  • 7.1 Site Master Planning – Part-I
    In this lesson, we take our first look at site master planning based on: planning rationale, assumptions, prerequisites, typical bulk production unit, site scope, flexibility, expandability, & future-proofing, determining size requirements, sizing & shaping, and broad rules.
  • 7.2 Classification of Clean Areas – Vial Filling 
    In these lessons, we look at: (1) how to classify areas for aseptic operations, (2) typical configurations of air handling units (AHU’s), terminal filters, zone air-inlets and -exhausts to support various classified environments, (3) filter arrangements in air handling units and in their supply air ducting, (4) particles limits associated with various classified air environments, and (5) viable microbial limits, measured as Colony Forming Units (CFU), associated with various classified air environments.
  • 7.3 Area Classification Protection
    In this lesson, we observe a range of airlock configurations typically used in combination under operational conditions to maintain the specification of critical environmental zones, such as those used in open processing, that have a major impact on product quality and patient. 
  • 7.4 Compress Air and Pneumatics 
  • 7.5 Aseptic Filling
    In this lesson, we describe the process equipment for the filling of medicinal vials aseptically in the sequence of: washing, dehydrogenation, filling and their subsequent inspection.
  • 7.6 Cleanroom Gowning
    In this lesson, we describe clothing that will minimize dispersion from skin and clothing for personnel working within a cleanroom environment.
  • 7.7 Aseptic Processing 
    In these lessons, we look at various manual and automated processes and facility layouts for vial filling operations.
  • 7.8 Cleanroom Monitoring – Physical Tests
    In this lesson, we discuss typical physical tests to monitor cleanroom environments: non-viable particle counts, pressure differentials, airflow velocity, air change rate, and filter integrity testing.
  • 7.9 Quality System – Evaluation Activities 
  • 7.10 Maintenance Management
    This lesson describes the processes and controls used in the delivery of maintenance services and work execution.

  • 8.1 Site Master Planning – Part-II
    We continue in this lesson exploring the configuration philosophy for a site specifically layering configuration options, fermentation/bioreactor, media and buffer preparation. We also look at the shaping and sizing options for fermentation, media preparation, buffer preparation, downstream processing, process and general utilities, buildings, and expansion.
  • 8.2 Open Versus Closed Processing  
  • 8.3 Facility Layout Concept 
  • 8.4 Blow/Fill/Seal Technology 
  • 8.5 PLC Programming
    In this lesson, we describe how to program a PLC to automate a machine using ladder logic diagrams.
  • 8.6 PLC Program Case Studies 
  • 8.7 Cleanroom Monitoring – Microbiological Tests
    In this lesson, we look at a range of typical microbiological measurements to monitor a cleanroom environment for conformance to specifications.
  • 8.8 Cleanroom Monitoring – Cleanrooms Cleaning Procedures 
  • 8.9 Terminally Sterilised Products 
  • 8.10 EU Guidelines on Cleanroom Aseptic Preparation 

  • 9.1 HVAC Critical Parameters for Sterile and Non-Sterile Manufacturing 
  • 9.2 Batch Process Control
    In this lesson, we discuss the ISA-88.01 modularization software standard for segmenting a process into physical entities, and into procedural models for instructional recipes. The physical model is used to describe equipment, and the procedural model used to describe recipes (process sequencing).
  • 9.3 Nitrogen Supply and Distribution
  • 9.4 Environmental Monitoring Program 
    In this lesson, we describe how to monitor a cleanroom environment in order to identify actual and potential sources of contamination using both physical and microbiological techniques.
  • 9.5 ICH Q10 – Pharmaceutical Quality System
    This lesson explains the concept of ‘continual improvement’ as part of a company’s quality management system and describes an effective corrective action process and a preventive action process (CAPA). It also gives details on the product-lifecycle for a pharmaceutical product and describes the monitoring of process performance and product quality.
  • 9.6 FDA Guidance on Aseptic Processing 

  • 10.1 Construction Lifecycle
    In the first lesson for construction lifecycle, we explore the following: choosing a construction type, substructure, options for super-structure, internal building fabric, mechanical installation, electrical & instrumentation, construction sequence for new build, constructability, construction management, construction safety, construction costs, schedule, and quality management. In the second lesson, we look at the contents of clean utility piping test packs. In the third lesson, we look at modular construction and sustainable construction.
  • 10.2 Software Functional Block Diagram (FBD)
  • 10.3 ASTM E 2500
    In this lesson, we review the ASTM International standard E 2500 – 07 ‘Standard Guide for Specification, Design, and Verification of Pharmaceutical and Biopharmaceutical Manufacturing Systems and Equipment’.

Develop a site master plan for an aseptic manufacturing process and the design of its environmental control and clean utility systems.

You will produce a number of deliverables during the course including:

  • Calculating Mass Balances and Equipment Sizing
  • Designing a Clean Utility generation and distribution system
  • Defining the cleanroom layout for safe material and personnel flows
  • Describing the Quality System necessary for manufacturing safe medicines

You will receive an end of course certificate from GetReskilled which along with others modules can build into an academic accreditation from the Technological University Dublin (Ireland) subject to the following criteria;

  • Passing a written or oral Exam on the materials.
  • The submission of all assessments and the end of module assignment.

Delivered by a Practicing Industry Expert

Dr.Joe Brady Lecturer at GetTeskilled

Dr. Joe Brady

Full-Time Validation Lead
Lecturer, Technological University Dublin, Ireland
Senior Associate, GetReskilled

Dr. Joe Brady is a full-time practicing Validation Lead and an assistant lecturer with Technological University Dublin (TU Dublin), in the School of Chemical and Pharmaceutical Sciences. Joe is a certified trainer and highly experienced in competency-based training. He designs and prepares educational modules and full academic courses ranging from MSc, MEngSc. BSc, to Certificate level, for a range of academic institution.

He is also a supervisor for MSc/MEngSc and PhD theses. Joe has over twenty years of project experience in the pharmaceutical, biopharmaceutical and medical device industries in Ireland, Singapore, China, The Netherlands, France and the USA.

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If you’re spending money on an education program, make sure you choose one you’ll finish!

With every GetReskilled ONLINE program;

  1. We use one centralized platform (Moodle) where you can log into your classroom anytime. Each week, you’ll watch videos and complete a series of quizzes, tests, interactive activities, and projects. The course materials are available 24/7 and nothing requires you to be online at a specific day or time. i.e there are NO ZOOM classes and NO WEBINARS! Study anywhere, anytime, for example after the kids have gone to bed or on the weekend.
  2. Your working schedules are unpredictable so we offer flexible delivery. Slow down, speed up or pause the delivery of the program.
  3. We release only one week’s worth of material at a time and then MANUALLY check your activity logs at the end of every week to make sure that you are keeping up with your work.
  4. You’ll have a dedicated course leader who will email or telephone you if it looks like you’re starting to fall behind. They will work with you to develop a study plan to get you back on schedule and finish the course.

This all helps us to spot any potential issues early and helps you completely finish the program.

How does Studying Online Work?

Show Off Your New Skills: Get a Certificate of Completion

Once the course is over, complete a written assignment to get certified in Principles of Pharmaceutical Facility Design

Add it to your resume, your LinkedIn profile or just get that well-earned raise you’ve been waiting for.

Pharmaceutical Facility Design

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11 Frequently Asked Questions

How do you keep track of my progress on the course?

We release only one week’s worth of material at a time and then check your activity logs weekly to make sure that you’re managing to keep up with your workload. This helps us to spot any potential issues early. There is a “Progress Bar “on your course which is helpful to you and us to know how you are doing.

You have a dedicated course leader who will follow up with you if it looks like you’re starting to fall behind. She’ll also be in touch weekly to let you know when new content is open for you.

Yes, this program is delivered fully online.

Each week of online content typically includes 6-10 topics.

Each topic includes:

  • A set of course notes – these provide additional depth to the video content.
  • Warm-up self-assessment question – to recap or activate any relevant prior learning.
  • A video – these are typically 5-15 minutes long and deliver 80% of the course content.
  • Post video self-assessment questions to check how well you can recall this new material from memory. If you can’t answer these questions, you should revisit that topic’s learning materials.
  • Any follow up assessments or assignments.

Yes

Yes, you can speed up or slow down the rate of delivery to suit your requirements. The most important thing is communication between you and your course coordinator. If you are taking a break or are busy at work and do not have time to study you need to tell her or him. Similarly, if you want to study at a faster rate, then just email in good time and ask for more course content.

Yes

No you don’t. The online classroom is open 24 hours a day so you do not have to login at any particular time. We will give you a Username and Password on the day the program starts and this allows you 24 hours a day access.

Yes

Yes

Yes

Yes for 6 months.

Price

Price for 1-Person

$999/month

for 3 months

Price for 1-Person