URS-Glass Washer
URS-Glass Washer
For
Document Number:
URS-Glass Washer
Citra-Labs
Braintree, MA
USER REQUIREMENTS SPECIFICATION
1. Approvals
This document is the governing document for the user requirements for a system that will rinse
glass bottles and will be referred to as the “glass washer” or “the system” in this document.
The undersigned individuals acknowledge that they have read and fully understand Citra Labs
LLC. user requirements and corresponding Factory Acceptance Testing (“FAT”) requirements.
Conflicts between this URS and the attachments referenced herein shall be controlled by this
URS if applicable.
Approved by:
Production Manager
Dhar Bharatula
The Quality Asssurance Manager is signing to confirm acceptance of the specifications and documented rationale.
This document is the property of Citra Labs LLC. The information is private and confidential
and is to be used only in occurrence with work directed by Citra Labs LLC. and no part of this to
be disclosed to others without written permission from Citra Labe LLC. Braintree, MA
1. Approvals....................................................................................................................2
2. Revision History.........................................................................................................4
3. Use of the User Requirement Specification (URS).................................................5
4. Purpose.......................................................................................................................5
5. References...................................................................................................................6
6. Equipment/System.....................................................................................................6
7. Product........................................................................................................................7
8. Performance Requirements......................................................................................8
9. Functional Requirements........................................................................................10
10. Power Failure and Recovery Requirements.......................................................10
11. Utilities Requirements..........................................................................................11
2. Revision History
Date of
Revision Revised By Title/Department Description of Change
Revision
Validation Engineer
A 02/08/2013 Matthew Hartman Barry-Wehmiller Design Issued for Review
Group
Validation Engineer Incorporated Vendor
B 02/18/2013 Matthew Hartman Barry-Wehmiller Design Exceptions. Issued for
Group Approval.
Citra Labs approval of the URS constitutes agreement by key users and stakeholders that all user
requirements are fairly and accurately represented. Any system designed and implemented in
accordance with the URS must meet the requirements listed herein. If the system does not meet a
listed requirement, justification must be provided to the key users and stakeholders for modifying
the specification. Acceptance by the key users and stakeholder of any changes must be
documented, along with the justification, and this URS must be updated, approved and re-issued.
Supplier-identified exceptions to this URS must be itemized in detail on the exception list by the
supplier in a timely manner and discussed and agreed with Citra Labs prior to any purchase order
being issued. In the event that no supplier exceptions are identified, it is understood that the URS
is acceptable in full as written. See Attachment 01 – Exception List.
4. Purpose
The purpose of this URS document is to define the user requirements for the batch style glass
washer. In this document it will be referred to as “the system.” The system is designed to rinse
glass bottles prior to depyrogenation and then filling with product.
This URS includes the requirements for the design, operation, and applicable performance
characteristics necessary to function as intended. The system will be fabricated, installed, and
verified to operate to the specifications outlined in this document. This URS is prepared by
Barry-Wehmiller Design Group (BWDG), representing Citra Labs.
The supplier shall accommodate the FAT package and deliver the system in accordance with this
specification, terms and conditions, and the accompanying information provided by Citra Labs.
This equipment will be installed and located at the Citra Labs Facility in Braintree, MA.
5. References
The equipment will be designed for compliance with the practices and principles as described in
the following guides:
GAMP 5
ISPE Baseline - Commissioning and Qualification
CE Conformity with the European Union Regulations
FDA Food and Drug Administration
NEMA - National Electrical Manufacturers Association
OSHA - Occupational and Safety Hazard Administration
UL - Underwrites Laboratories
6. Equipment/System
6.1. Overview
The system will be installed in an ISO 8 environmentally controlled room.
The system will process 110 bottles per load for the 30mL bottle size. Additionally,
the system will be capable of (although not provided with the change parts for)
processing 284 bottles per load for the 5mL bottle size and 60 bottles per load for the
50mL bottle size.
The system will be capable of rinsing all internal and external surfaces of the bottles.
The system will be able to provide a multiple stage bottle rinse and air blowing cycle.
Water for Injection (WFI) will be drawn directly from the WFI supply loop at 80°C.
Compressed air for the bottle air blowing cycle will be 0.2 micron filtered.
The complete System shall include, at a minimum:
o 316L stainless steel injection needles, piping, basin, and top cover.
o One loading plate of 316L stainless steel for 30mL. Additionaly, the system must
be capable of housing plates to rinse 5 mL and 50 mL vials.
o 304 stainless steel exterior. All external surfaces, including base, must be
compatible with materials of cleaning.
o The glass washer will have an independent human machine interface (HMI) and
programmable logic controller (PLC).
6.2. Description
The system will employ a series of WFI and filtered air injections to rinse the internal and
external surfaces of the bottles. The operation of the system will be controlled and monitored
by a dedicated PLC. The operator will have access to the system control, status, alarms, and
messages by use of a dedicated HMI.
To initiate the cycle, the operator will manually de-bag and load bottles onto the loading
plate. Once fully populated, the operator will then insert the loading plate into the glass
washer through the top hatch and secure the hatch closed. The operator will then select the
appropriate cycle from the HMI and activate the system by pressing the start button.
The bottles will be subjected to a series of internal rinse and air blowing sequences delivered
through stainless steel injection needles centered on the interior of each bottle. External
surfaces will undergo a rinse and air blowing sequence delivered by rotating wands situated
above the bottles. WFI will be used for each rinse sequence. After each rinse sequence, the
bottles will be air blowed by filtered, compressed air. Following a successful completed
cycle, the operator will remove the loading plate with the rinsed bottles from the glass
washer.
7. Product
The system will handle, rinse, and air blow 30mL glass bottles and be capable of rinsing 5 mL
and 50 mL glass bottles utilizing different needle plates. See Attachment 02 – Bottle Drawings
for detailed bottle drawings.
8. Performance Requirements
8.2. Rinsing
ID Number Requirement Description
The system shall be capable of rinsing all internal and external surfaces of
URS-ID-8
the bottles.
The system shall be capable of rinsing away all visually detectable levels
URS-ID-9 of particles, dirt, dust, packaging materials, or other contaminants on the
bottles.
8.2. Rinsing
ID Number Requirement Description
The system shall pass riboflavin testing as follows:
A homogeneous solution of riboflavin (consisting of 1 gram of
riboflavin per 10 liters of cold WFI) shall be slowly sprayed on
the interior top and side walls of the glass bottles. Excess will be
drained.
The bottles will undergo a pre-rinse visual inspection with a long-
URS-ID-10 range wave-length UV lamp for uncovered spots, sprayed again
(as needed), and drained again (as needed).
The bottles will undergo the rinse cycle.
After the rinse cycle, the longrange wavelength UV lamp will be
used for a post-rinse inspection, checking for remaining traces of
riboflavin. There shall be no traces of riboflavin on the glass
bottles after the rinse cycle.
9. Functional Requirements
9.2. Operation
ID Number Requirement Description
The system shall be capable of running programmable, multi-stage rinse
URS-ID-18
and air blow cycles (up to 18 stages).
URS-ID-19 The system cycle shall be initiated by the push of a single start button.
The system shall be equipped with an HMI that provides cycle control,
URS-ID-20
system status, alarms, messages and reset capabilities.
11.1. Utilities
ID Number Requirement Description
The system shall be designed and fabricated to operate using the
following available primary utilities:
URS-ID-23 Electrical Power: 120VAC, 60 Hz, Single-Phase
Clean Compressed Air: 90 PSI
WFI: 10-50 PSI, 80°C, 0.1 GPM per Nozzle
All power and compressed air for the equipment will be connected in the
URS-ID-24
clean room area.
URS-ID-25 Drainage shall be adequate to prevent back-up.
12.1. Cleaning
ID Number Requirement Description
All exterior surfaces will be smooth and free of catch points to permit
URS-ID-26
ease of wipe-down cleaning and sanitation procedures.
All surfaces, including base frame, shall be compatible with Septihol or
URS-ID-27
equivalent.
13.3. E-Stops
ID Number Requirement Description
The system shall contain minimally one E-stop button located at the
URS-ID-38
operator interface for hard stop of the equipment.
The E-Stop system shall stop motion of all moving parts and remove or
URS-ID-39 control all hazardous energy sources before someone could reach a
hazard.
The system shall be designed to handle the stress of an emergency stop
URS-ID-40
without damage.
URS-ID-41 The E-Stop mechanism shall override all other system controls.
The E-Stop mechanism shall require a manual reset prior to re-starting the
URS-ID-42
system.
13.4. Lockout
ID Number Requirement Description
The electrical panel is to be provided with a UL approved disconnect
URS-ID-43
switch which will disconnect the utility power.
14.1. Security
ID Number Requirement Description
The HMI, at a minimum, shall display controls, system status, alarms,
URS-ID-46
and messages.
Three levels of password protected screens must be provided as follows:
Default (No Password): System status, alarms, and messages.
URS-ID-47 Operator: In addition to default capabilities, cycle controls.
Administrator: In addition to Operator capabilities, cycle
parameter adjustment.
Operator and Administrator screens must have a time out function that
URS-ID-48 reverts to the login screen after a period of inactivity no greater than 15
minutes.
14.2. Faults/Alarms
ID Number Requirement Description
URS-ID-49 Sensors for alarm and fault conditions shall be included.
User documentation must include a list of the possible error or fault
URS-ID-50 conditions, the corresponding error codes, disposition, means of
triggering alarms, and reset sequence.
14.2. Faults/Alarms
ID Number Requirement Description
The system shall provide alarms for:
URS-ID-51
Emergency stop
15.3. Data
ID Number Requirement Description
System PLC shall be capable of communicating with client’s network via
URS-ID-58
Ethernet Protocol.
Provide an Ethernet Hub within the Control Panel that has allowance for
URS-ID-59 client’s network Ethernet cable to be plugged in, as well as one spare port
for diagnostic purposes.
16.2. Wiring
ID Number Requirement Description
Not more than two wires shall be connected to any side of a terminal
URS-ID-67
block.
10% reserve terminals, including power and controls in each panel, shall
URS-ID-68
be provided.
URS-ID-69 Power and control wiring shall be routed separately.
URS-ID-70 Conductors must run from terminal to terminal without splices.
Individual shields shall be provided for all analog twisted pairs leaving
URS-ID-71
the PLC panel.
Shields shall run from the instrument to the PLC panel. Shields shall be
URS-ID-72
grounded at the PLC panel only.
16.2. Wiring
ID Number Requirement Description
Each field device feedback signal shall be committed to a single
URS-ID-73
controller input.
URS-ID-74 Only one output device shall be wired to any single controller output.
Each field device shall be labeled in English in a manner that makes it
URS-ID-75
easy to relate to the electrical schematics and the controller program.
Field device wires shall be clearly identified by a durable method.
URS-ID-76
Markings shall correspond with the Supplier's drawings.
Each field device shall have a continuous connection to the main control
URS-ID-77 panel. Daisy chaining of power and return in the field is not permitted,
except in the case of the “E-Stop” circuit.
Controller I/O wiring shall be numbered in a manner that references its
URS-ID-78
address on the I/O module.
URS-ID-79 Wire ferules will be used for all terminal block terminations.
The use of wire nuts, solderless splices, or crimp splices is prohibited; all
URS-ID-80
wire connections will be done with terminal blocks.
Wires shall be numbered on both ends, in a method corresponding to the
URS-ID-81
electrical schematics.
All wiring shall be installed in plastic troughs (wireway). A minimum of
URS-ID-82 30% spare space shall be provided in the wireway. Wires shall be neatly
bundled and secured within the wireway.
17.1. Maintenance
ID Number Requirement Description
A list of the spare parts expected to be required within the first year of
URS-ID-83 operation, along with the spare part numbers, prices and quantities
required shall be provided.
Substances required for operation of the system, such as lubricants, shall
URS-ID-84
not contact product.
All lubricants must be approved by the FDA for incidental or direct
URS-ID-85
product contact and shall be non-flammable.
All bearings, gearboxes and other mechanical contact surfaces requiring
URS-ID-86 lubrication must be per the manufacturer’s specification prior to start-up
and operation of the equipment.
URS-ID-87 All lubrication points shall be easily accessible.
17.4. Pneumatics
ID Number Requirement Description
All pressure regulators, air filters, etc., required shall be part of
URS-ID-95 equipment, and located together at a convenient location for periodic
adjustments and service.
URS-ID-96 Equipment shall have only one inlet for compressed air source.
URS-ID-97 All air exhausts shall be silenced as long as function is not compromised.
19.1. Documentation
ID Number Requirement Description
All manuals and drawing text must be in English supplied in PDF format.
URS-ID-99
Drawings shall be supplied in AutoCAD compatible format.
Documentation from the supplier shall include:
Model/Serial Number of equipment on the Operations Manual
Process and Instrumentation Diagram (P&ID)
Application Software – Electronic copy – of all PLC and
applicable HMI programs.
Electrical Drawings
Pneumatic Drawings
Layout Drawings
List of devices requiring calibration
Bill of Materials
URS-ID-100
Stock Literature (literature for off-the-shelf components - motors,
relays, etc)
Change Parts List
Spare Parts List
Lubricant List
Operation and Maintenance Manual
Alarm and Fault List
Preventive Maintenance Schedule
Trouble Shooting Guide
Applicable MSDS’
Draft versions of the Manuals and drawings shall be provided four weeks
URS-ID-101
prior to Factory Acceptance Test (FAT).
Final versions of the Manuals and drawings shall be provided at the time
URS-ID-102 of FAT. Verification for accuracy will be conducted during FAT
execution and redlined corrections made as necessary.
19.1. Documentation
ID Number Requirement Description
The supplier will provide installation instructions and drawings at the
time of FAT. This will include size, dimensions and pick up points of
URS-ID-103
crating. A review of the instructions/drawings will be made at FAT and
corrections made as necessary.
21. Attachments
01 – Exception List
02 – Bottle Drawings









