PILOT PLANT SCALE- UP TECHNIQUE

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PILOT PLANT SCALE- UP TECHNIQUE

• Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D
• Professor of Pharmaceutics
• Department of Pharmaceutics
• KLE University College of Pharmacy
• BELGAUM 590010, Karnataka, INDIA

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Contents

• Definition
• Objectives
• Steps in scale-up
• General considerations
• GMP considerations
• Advantages and Disadvantages
• Scale up of liquid dosage forms.
• Scale up of semisolid dosage forms.
• Contract manufacturing.
• References

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Definitions

• Plant- It is a place were the 5 Ms like money,
  material, man, method and machine are brought
  together for the manufacturing of the products.
• Pilot Plant- It is the part of the
  pharmaceutical industry where a lab scale formula
  is transformed into a viable product by
  development of liable and practical procedure of
  manufacture.
• Scale-up- The art for designing of prototype
  using the data obtained from the pilot plant
  model.

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Objective

• To try the process on a model of proposed plant
  before committing large sum of money on a
  production unit.
• Examination of the formula to determine its
  ability to withstand Batch-scale and process
  modification.
• Evaluation and Validation for process and
  equipments

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Objective

• To identify the critical features of the process
• Guidelines for production and process controls.
• To provide master manufacturing formula with
  instructions for manufacturing procedure.
• To avoid the scale-up problems.

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STEPS IN SCALE UP
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Define product economics based on projected
market size and competitive selling and provide
guidance for allowable manufacturing costs
Conduct laboratory studies and scale-up planning
at the same time
Define key rate-controlling steps in the proposed
process
Conduct preliminary larger-than-laboratory
studies with equipment to be used in
rate-controlling step to aid in plant design
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Design and construct a pilot plant including
provisions for process and environmental
controls, cleaning and sanitizing systems,
packaging and waste handling systems, and
meeting regulatory agency requirements
Evaluate pilot plant results (product and
process) including process Economics to make any
corrections and a decision on whether or not to
proceed with a full scale plant development
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Why conduct Pilot Plant Studies?

• A pilot plant allows investigation of a product
  and process on an intermediate scale before large
  amounts of money are committed to full-scale
  production.
• It is usually not possible to predict the effects
  of a many-fold increase in scale.
• It is not possible to design a large scale
  processing plant from laboratory data alone with
  any degree of success.

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A pilot plant can be used for

• Evaluating the results of laboratory studies and
  making product and process corrections and
  improvements.
• Producing small quantities of product for
  sensory, chemical, microbiological evaluations,
  limited market testing or furnishing samples to
  potential customers, shelf-life and storage
  stability studies.
• Providing data that can be used in making a
  decision on whether or not to proceed to a
  full-scale production process and in the case of
  a positive decision, designing and constructing a
  full-size plant or modifying an existing plant

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General considerations

• Reporting Responsibility

The formulator who developed the product can take
into the production and can provide support
even after transition into production has been
completed
R D group with separate staffing
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2. Personnel Requirement

• Scientists with experience in pilot
  plant operations as well as in actual production
  area are the most preferable.
• As they have to understand the intent of
  the formulator as well as understand the
  perspective of the production personnel.
• The group should have some personnel with
  engineering knowledge as well as scale up also
  involves engineering principles.

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• 3. Space Requirements

Standard equipment floor space
Storage area
Administration and information processing
Physical testing area
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• Administration and information process
• Adequate office and desk space should be
  provided for both scientist and technicians.
• The space should be adjacent to the working
  area.

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• Physical testing area-
• This area should provide permanent bench top
  space for routinely used physical- testing
  equipment.

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• Standard pilot-plant equipment floor space-
• Discreet pilot plant space, where the
  equipment needed for manufacturing all types of
  dosage form is located.
• Intermediate sized and full scale
  production equipment is essential in evaluating
  the effects of scale-up of research formulations
  and processes.
• Equipments used should be made portable where
  ever possible. So that after use it can be stored
  in the small store room.
• Space for cleaning of the equipment should be
  also provided.

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• Storage Area-

• It should have two areas divided as approved
  and unapproved area for active ingredient as well
  as excipient.
• Different areas should provided for the
  storage of the in-process materials, finished
  bulk products from the pilot-plant materials
  from the experimental scale-up batches made in
  the production.
• Storage area for the packing material should
  also be provided.

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• 4. Review of the formula
• A thorough review of the each aspect of
  formulation is important.
• The purpose of each ingredient and its
  contribution to the final product manufactured on
  the small-scale laboratory equipment should be
  understood.
• Then the effect of scale-up using equipment
  that may subject the product to stresses of
  different types and degrees can more readily be
  predicted, or recognized.

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• 5. Raw materials-
• One purpose/responsibility of the pilot-plant
  is the approval validation of the active
  ingredient excipients raw materials.
• Raw materials used in the small scale
  production cannot necessarily be the
  representative for the large scale production

Why?
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• 6. Equipment-
• The most economical and the simplest
  efficient equipment which are capable of
  producing product within the proposed
  specifications are used.
• The size of the equipment should be such that
  the experimental trials run should be relevant to
  the production sized batches.
• If the equipment is too small the process
  developed will not scale up,
• Whereas if equipment is too big then the
  wastage of the expensive active ingredients.

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• 7. Production Rates-
• The immediate as well as the future market
  trends/requirements are considered while
  determining the production rates.

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• 8. Process Evaluation-

Order of mixing of components
Drying temp. And drying time
Mixing speed
Screen size (solids)
PARAMETERS
Mixing time
Rate of addition of granulating agents,
solvents, solutions of drug etc.
Filters size (liquids)
Heating and cooling Rates
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• Why to carry out process evaluation????
• The knowledge of the effects of various process
  parameters as few mentioned above form the basis
  for process optimization and validation.

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• 9. Master Manufacturing Procedures-
• The three important aspects

Processing directions
Manufacturing procedure
Weight sheet
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Master Manufacturing Procedures

• The weight sheet should clearly identify the
  chemicals required In a batch. To prevent
  confusion the names and identifying nos. for the
  ingredients should be used on batch records.
• The process directions should be precise and
  explicit.
• A manufacturing procedure should be written by
  the actual operator.
• Various specifications like addition rates,
  mixing time, mixing speed, heating, and cooling
  rates, temperature, storing of the finished
  product samples should be mentioned in the batch
  record directions.

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• 10. Product stability and uniformity-
• The primary objective of the pilot plant is
  the physical as well as chemical stability of the
  products.
• Hence each pilot batch representing the final
  formulation and manufacturing procedure should be
  studied for stability.
• Stability studies should be carried out in
  finished packages as well.

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GMP CONSIDERATION

• Equipment qualification
• Process validation
• Regularly schedule preventative maintenance
• Regularly process review revalidation
• Relevant written standard operating procedures
• The use of competent technically qualified
  personnel
• Adequate provision for training of personnel
• A well-defined technology transfer system
• Validated cleaning procedures.
• An orderly arrangement of equipment so as to ease
  material flow prevent cross- contamination

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Advantages

• Members of the production and quality control
  divisions can readily observe scale up runs.
• Supplies of excipients drugs, cleared by the
  quality control division, can be drawn from the
  more spacious areas provided to the production
  division.
• Access to engineering department personnel is
  provided for equipment installation, maintenance
  and repair.

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Disadvantages

• The frequency of direct interaction of the
  formulator with the production personnel in the
  manufacturing area will be reduced.
• Any problem in manufacturing will be directed
  towards its own pilot-plant personnel's.

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Scale up of liquid orals
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Liquid orals

• The physical form of a drug product that is
  pourable displays Newtonian or pseudo plastic
  flow behavior and conforms to its container at
  room temperature.
• Liquid dosage forms may be dispersed systems or
  solutions.
• In dispersed systems there are two or more
  phases, where one phase is distributed in
  another.
• A solution refers two or more substances mixed
  homogeneously.

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Steps of liquid manufacturing process

• Planning of material requirements
• Liquid preparation
• Filling and Packing
• Quality assurance

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Critical aspects of liquid manufacturing

• Physical Plant
• Heating, ventilation and air controlling system
• The effect of long processing times at
  suboptimal temperatures should be considered in
  terms of consequences on the physical or chemical
  stability of ingredients as well as product.

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Formulation aspects of oral liquids

• Suspensions

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Formulation aspects of oral liquids

• Emulsions

• Emulsions

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Formulation aspects of oral liquids

• Solutions

• Solutions

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Layout of the pilot plant
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Equipments

• Mixer
• Homogenizer
• Filteration assembly
• Bottling assembly

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Filtration assembly
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General flow chart
Raw Materials
Measured and weighed
Mixing
Distilled water
Filling
Packing
Finished products storage
Quality Assurance
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Quality assurance

• Dissolution of drugs in solution
• Potency of drugs in suspension
• Temperature uniformity in emulsions
• Microbiological control
• Product uniformity
• Final volume
• Stability

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Scale-up of semisolid dosage forms
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Semisolid dosage forms

• In general, semisolid dosage forms are complex
  formulations having complex structural elements.
• Often they are composed of two phases (oil and
  water), one of which is a continuous (external)
  phase, and the other of which is a dispersed
  (internal) phase.
• The active ingredient is often dissolved in one
  phase, although occasionally the drug is not
  fully soluble in the system and is dispersed in
  one or both phases, thus creating a three-phase
  system.

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Semisolid dosage forms

• The physical properties of the dosage form depend
  upon various factors, including the size of the
  dispersed particles, the interfacial tension
  between the phases, the partition coefficient of
  the active ingredient between the phases, and the
  product rheology.
• These factors combine to determine the release
  characteristics of the drug, as well as other
  characteristics, such as viscosity.

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Critical manufacturing parameters

• For a true solution, the order in which solutes
  are added to the solvent is usually unimportant.
• The same cannot be said for dispersed
  formulations, however, because dispersed matter
  can distribute differently depending on to which
  phase a particulate substance is added.
• In a typical manufacturing process, the critical
  points are generally the initial separation of a
  one-phase system into two phases and the point at
  which the active ingredient is added.

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Critical manufacturing parameters

• Because the solubility of each added ingredient
  is important for determining whether a mixture is
  visually a single homogeneous phase, such data,
  possibly supported by optical microscopy, should
  usually be available for review.
• This is particularly important for solutes added
  to the formulation at a concentration near or
  exceeding that of their solubility at any
  temperature to which the product may be exposed.

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Critical manufacturing parameters

• Variations in the manufacturing procedure that
  occur after either of these events are likely to
  be critical to the characteristics of the
  finished product.
• This is especially true of any process intended
  to increase the degree of dispersion through
  reducing droplet or particle size (e.g.,
  homogenization).
• Aging of the finished bulk formulation prior to
  packaging is critical and should be specifically
  addressed in process validation studies.

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General stability consideration

• The effect that SUPAC changes may have on the
  stability of the drug product should be
  evaluated. For general guidance on conducting
  stability studies, see the FDA Guideline for
  Submitting Documentation for the Stability of
  Human Drugs and Biologics.

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General stability consideration

• For SUPAC submissions, the following points
  should also be considered
• In most cases, except those involving scale-up,
  stability data from pilot scale batches will be
  acceptable to support the proposed change.
• 2. Where stability data show a trend towards
  potency loss or degradant increase under
  accelerated conditions, it is recommended that
  historical accelerated stability data from a
  representative prechange batch be submitted for
  comparison.

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General stability consideration

• It is also recommended that under these
  circumstances, all available long-term data on
  test batches from ongoing studies be provided in
  the supplement.
• Submission of historical accelerated and
  available long-term data would facilitate review
  and approval of the supplement.

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General stability consideration

• 3. A commitment should be included to conduct
  long-term stability studies through the
  expiration dating period, according to the
  approved protocol, on either the first or first
  three (see section III-VI for details) production
  batches, and to report the results in subsequent
  annual reports.

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The Role of In Vitro Release Testing

• The key parameter for any drug product is its
  efficacy as demonstrated in controlled clinical
  trials.
• The time and expense associated with such trials
  make them unsuitable as routine quality control
  methods.
• Therefore, in vitro surrogate tests are often
  used to assure that product quality and
  performance are maintained over time and in the
  presence of change.

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The Role of In Vitro Release Testing

• A variety of physical and chemical tests commonly
  performed on semisolid products and their
  components (e.g., solubility, particle size and
  crystalline form of the active component,
  viscosity, and homogeneity of the product) have
  historically provided reasonable evidence of
  consistent performance.
• More recently, in vitro release testing has shown
  promise as a means to comprehensively assure
  consistent delivery of the active component(s)
  from semisolid products.

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The Role of In Vitro Release Testing

• An in vitro release rate can reflect the combined
  effect of several physical and chemical
  parameters, including solubility and particle
  size of the active ingredient and rheological
  properties of the dosage form. In most cases, in
  vitro release rate is a useful test to assess
  product sameness between prechange and postchange
  products.

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The Role of In Vitro Release Testing

• However, there may be instances where it is not
  suitable for this purpose. In such cases, other
  physical and chemical tests to be used as
  measures of sameness should be proposed and
  discussed with the Agency.
• With any test, the metrics and statistical
  approaches to documentation of sameness in
  quality attributes should be considered

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The Role of In Vitro Release Testing

• The evidence available at this time for the in
  vitro-in vivo correlation of release tests for
  semisolid dosage forms is not as convincing as
  that for in vitro dissolution as a surrogate for
  in vivo bioavailability of solid oral dosage
  forms.
• Therefore, the Centers current position
  concerning in vitro release testing is as follows

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The Role of In Vitro Release Testing

• In vitro release testing is a useful test to
  assess product sameness under certain scale-up
  and postapproval changes for semisolid products.
• 2. The development and validation of an in vitro
  release test are not required for approval of an
  NDA, ANDA or AADA nor is the in vitro release
  test required as a routine batch-to-batch quality
  control test.

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The Role of In Vitro Release Testing

• 3. In vitro release testing, alone, is not a
  surrogate test for in vivo bioavailability or
  bioequivalence.
• 4. The in vitro release rate should not be used
  for comparing different formulations across
  manufacturers.

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Contract manufacturing
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Definition of contract manufacturing

• Production of goods by one firm, under the label
  or brand of another firm. Contract
  manufacturers provide such service to several
  (even competing) firms based on their own or
  the customers' designs, formulas, and/or
  specifications. Also called private label
  manufacturing.

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Contract manufacturing

• Contract manufacturing is a process that
  established a working agreement between two
  companies.
• As part of the agreement, one company will custom
  produce parts or other materials on behalf of
  their client.
• In most cases, the manufacturer will also handle
  the ordering and shipment processes for the
  client.
• As a result, the client does not have to maintain
  manufacturing facilities, purchase raw materials,
  or hire labour in order to produce the finished
  goods.

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Contract manufacturing.

• The basic working model used by
  contract manufacturers translates well into many
  different industries.
• Since the process is essentially outsourcing produ
  ction to a partner who will privately brand the
  end product, there are a number of different
  business ventures that can make use of a contract
  manufacturing arrangement.
• There are a number of examples of pharmaceutical
  contract manufacturing currently functioning
  today, as well as similar arrangements in food
  manufacturing, the creation of computer components
  and other forms of electronic contract
  manufacturing.

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Contract manufacturing

• Even industries like personal care and hygiene
  products, automotive parts, and medical supplies
  are often created under the terms of a contract
  manufacture agreement.
• In order to secure contract manufacturing jobs,
  the contract manufacturer usually initiates
  discussions with the potential client.
• The task is to convince the prospective customer
  that the manufacturer can use their facilities to
  produce quality goods that will meet or exceed
  the expectations of the customer.

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Contract manufacturing

• At the same time, the manufacturer will
  demonstrate how the overall unit cost of
  production to the customer will be less than any
  current production strategies in use, thus
  increasing the amount of profit that will be
  earned from each unit sold
• There are several advantages to a contract
  manufacturing arrangement.
• For the manufacturer, there is the guarantee of
  steady work.
• Having contracts in place that commit to certain
  levels of production for one, two and even five
  year periods makes it much easier to forecast the
  future financial stability of the company.

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Contract manufacturing

• For the client, there is no need to purchase or
  rent production facilities, buy equipment,
  purchase raw materials, or hire and train
  employees to produce the goods.
• There are also no headaches from dealing with
  employees who fail to report to work, equipment
  that breaks down, or any of the other minor
  details that any manufacturing company must face
  daily.

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Contract manufacturing

• All the client has to do is generate sales,
  forward orders to the manufacturer, and keep
  accurate records of all income and expenses
  associated with the business venture.
• The general concept of contract manufacturing is
  not limited to the production of goods. Services
  such as telecommunications, Internet access, and
  cellular services can also be supplied by a
  central vendor and private branded for other
  customers who wish to sell those services.
• Doing so allows the customer to establish a buy
  rate from the vendor, then resell the services at
  a profit to their own client base

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Scopes of contract manufacturing

• The scope of the Contract Manufacturing
  Procurement business scenario outlined in this
  documentation only concerns the customer side
  (OED -The Office of Enterprise Development ).
• This business scenario does not cover how an ERP
  (Enterprise Relationship Management) system on
  the supplier's side (that is, the contract
  manufacturer's side) receives messages sent by
  the customer, and how it deals with the
  additional information (for example, components)
  submitted with these messages.

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Scopes of contract manufacturing

• Mappings are only provided for A2A communication
  (between the OED's ERP system and SAP SNC) from
  IDoc to XML and vice versa.
• This business scenario does not cover the
  tracking of the manufacturing process (production
  phases) that takes place at the contract
  manufacturer's site - it does not take into
  account the current production phase at the
  contract manufacturer' site.
• Consequently, the OED planner cannot predict the
  supply situation of finished goods.
• SAP- Supply Network Planning
• SNC- Supply Network Collaboration

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Limits of contract manufacturing

• The Contract Manufacturing Procurement business
  scenario has the following limitations
• Once a schedule line in the ERP purchase order is
  changed, the date and quantity data originally
  requested are lost. Even if the information is
  stored in SAP SNC, it is not possible to send
  this information to the CM.
• The Contract Manufacturing Procurement business
  scenario is based on functions introduced in SAP
  ERP 6.0. For lower releases, you need to develop
  a customer modification.

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Limits of contract manufacturing

• No data import control functions are provided for
  messages sent from the CM to SAP SNC.
• The bill of material (BOM) is not available in
  SAP SNC.
• New purchase order items cannot be created in SAP
  SNC.
• Product substitution is not supported.
• Scheduling agreements for the subcontracted
  material are not allowed.

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Limits of contract manufacturing

• A supplier should be able to update the component
  consumption in SAP SNC until a good receipt has
  been posted in the customer ERP back-end system.
• The subcontracting scenario of the Rosetta
  Network Order Management Program as described in
  the PIPs 7B5 (Notify of Manufacturing Work
  Order), 7B6 (Notify of Manufacturing Work Order
  Reply), and 7B1 (Work In Process Notification) is
  not included in the scope of SAP SCM.
• PIP- Partner Interface Process
• SCM- Supply Chain Management

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Reference

• The theory practice of industrial pharmacy by
  Leon Lachman, Herbert A. Lieberman, Joseph L.
  kenig, 3rd edition, published by Varghese
  Publishing house.
• Lachman L. The Theory and practice of industrial
  pharmacy. 3rd Edition. Varghese publication
  house.
• www.google.com

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E-mail bknanjwade_at_yahoo.co.in Cell
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