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Best Practices and Points to Consider in Aseptic Processing

Sep 05 - Sep 06, 2019 |
Sep 06, 2019 |
Sheraton Munich Arabellapark Hotel | Munich, Germany
  • Education
  • Europe
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Aim of this training course is to facilitate a deeper understanding and provide insights into the Aseptic Processing environment, and to go beyond what is commonly covered in books on that subject. A practical and highly interactive approach will enable participants to get actively involved, discussing guidelines and Warning Letters in addition to sharing perspectives and solutions to issues found in everyday job situations.

A kaleidoscope of hot topics such as Best Practices and Case Studies from different areas of Aseptic Processing, Sterile Production facilities, QA/ QC Microbiology Control, Shop Floor Mentoring and Oversight will be addressed. Training and Motivation of staff, use of Risk Assessments and Quality Culture are further relevant aspects.

Lively interactions will make this a valuable learning experience for all.

Who Should Attend

Personnel involved in Aseptic Processing from sterile production departments such as:

  • Production Management and Shop Floor Supervisors
  • QA and QC Microbiologists
  • Qualified Persons
  • Personnel from technical department

A basic understanding of Aseptic Processing is a prerequisite.

Learning Objectives

  • Gain deeper knowledge and insights into specific topics like sterilization, training and motivation of shop-floor staff, correct aseptic working practices, media fill worst case criteria, effective environmental monitoring programs, good cleaning & disinfection practices, etc.
  • Understand key requirements and challenges in parenteral production
  • Understand the importance of a good quality culture within a company
  • Apply the executed and presented case studies and team exercises in her/his daily job
  • Get answers and interpretations about - potentially - unresolved questions and problems
  • Gain confidence for audits


Guenther Gapp, PhD, Independent Consultant, Gapp Quality GmbH
Since 2013, the microbiologist Guenther Gapp has been working as an independent consultant for different clients around the globe, and has been engaged in more than 30 projects: recently at US- Lachman Consultants as “Aseptic Processing Expert”, e.g. in assignments for remediation of companies cited with a Warning letter. In the previous steps of his career, he served in the pharmaceutical industry during 20 years as Head of QA/QC Microbiology department and Sterility Assurance Expert and Troubleshooter in global projects and supplier audits. During this period, he gained in-depth experience in Aseptic processing key elements, Training and motivation of operators, media fill practices of finished dosage forms and bulk products, environmental monitoring, rapid testing methods and regulatory agency audits. Guenther has been a subject matter expert in more than 20 FDA audits. He also created a new sterile risk assessment tool to identify and reduce the microbial contamination and compliance risk of aseptically prepared, sterile products, and this method is used now worldwide. The publication of this Risk Assessment tool won him the 2011 PDA Journal of Pharmaceutical Science and Technology Award. He has been a speaker at several PDA conferences in the past years. Since 2017 he is also a member of the 2017 PDA Annex 1 Workshop committee and Task Force, which deals with the revision of the important European guidance Eudralex Annex 1 “Manufacture of Sterile Medicinal Products”.

Wednesday, 05 September 2019

Welcome and Collection of Participant Expectations

Introductional Test about Selected Hot Topics in Aseptic Processing

  • Discussion of answers

Coffee Break

Important Aspects of Sterilization, Cleaning and Disinfection, Gowning Procedures

  • Steam & Dry Heat Sterilization
    • Technical Report 1 (TR 1) Validation of Moist Heat Sterilization Processes: Cycle Design, Development, Qualification
    • TR 3 Validation of Dry Heat Processes Used for Depyrogenation and Sterilization
    • TR 48 Moist Heat Sterilizer Systems: Design, Commissioning, Operation, Qualification and Maintenance
    • TR 61 Steam in Place
  • Key elements for Cleaning & Disinfection in cleanrooms
    • TR 70 Fundamentals of Cleaning and Disinfection Programs for Aseptic Manufacturing
  • Gowning steps for entering grade A/B area

Lunch Break

Aspects of Clean Room Concepts and Good Aseptic Working Practices

  • Conventional filling lines
  • RABS systems and isolators
  • Understanding First Air and barrier concepts
    • TR 62 Recommended Practices for Manual Aseptic Processes
  • Points to Consider for Aseptic Processing: Part 1 & Part 2
  • Update on TR 34 Design and Validation of Isolator Systems for the Manufacturing and Testing of Health Care Products

Team Excercise 1: How to Maintain an Aseptic Environment

Coffee Break

Effective Oversight at the shop floor, Good Training Methods

  • Regulatory requirements and framework
  • Sharing my best practices and effectiveness
  • Examples from the shop floor worldwide

End of Day 1

Thursday, 06 September 2019

Best Practices in Aseptic Processing Simulation

  • Basic Concepts and Regulatory Framework about Process Simulations
  • Best Practices in Media Fills for Finished Dosage Form and API
    • TR 22 Process Simulation for Aseptically Filled Products
    • TR 28 Process Simulation Testing for Sterile Bulk Pharmaceutical Chemicals
  • (Re)Qualification of Operators
  • Categorization of Interventions

EU Annex 1 Revision

  • Selected Comments from the PDA Taskforce

Coffee Break

Important Aspects in Environmental Monitoring

  • TR 13 Fundamentals of an Environmental Monitoring Program
  • Regulatory requirements and expectations
  • Rationale for sample locations and frequency
  • How to proceed in case of excursions

Team Exercise 2: Set-up a EM Program for Cleanrooms/Isolators

Lunch Break

Team Exercise 3: Share your own case studies and problems, and find resolutions as a team

Coffee Break

Team Exercise 4: Benchmarking between team members

End of Course

3 Ways to register

Please remember to log in if you are a member of PDA already! 

If you come from a Governmental or Health Authority Institution or from an Academic Organization please contact Ms. Antje Petzholdt before registering. She will verify your status and register you.

  • All registrations which will involve visa matters will have to be submitted to PDA EU four weeks prior to the start of the event at the latest. For later registrations, PDA Europe will be unable to assist participants in any visa affairs.
  • All costs incurring in connection with visa affairs shall be borne by registrants. (This applies in particular to costs for submitting documents by courier.)
  • Potential participants must be clients of UPS shipping agency and submit their UPS customer reference number to PDA EU (together with their registration).
  • No PDA membership obtainable upon booking training course, workshop or other related event.

Registration Fees

Are you entiteld to receive a discount? Need Help?

All Participants

1595 Euro


Antje PetzholdtAntje Petzholdt
Manager Registration, Chapters & Membership
Tel: +49 (0) 30 43 655 08-10
Fax: +49 (0) 30 43 655 08-66

Sheraton Munich Arabellapark Hotel
Arabellastreet 5
81925 Munich
Hotel Website
Tel.: +49 (0)89 92320

The elegant 4-star Sheraton Munich Arabellapark Hotel offers a soundproof accommodation in a residential area of Munich. Featuring chic architecture, the hotel was renovated in 2007. The property is located in Bogenhausen district, 3.5 km from Marienplatz. The city center lies within 4 km from the venue.

A spectacular view over the countryside welcomes guests to club superior king suite, junior king suite and executive flat with modern-style décor. The property boasts views of Alps from its rooms. Room facilities also include a microwave, an electric kettle and coffee/tea makers for self-catering. The property is in a 5-minute walking distance from Richard-Strauss-Straße subway station. It will take 35 minutes to get to Franz Josef Strauss airport by car.

PDA Europe has reserved a limited number of rooms until the 15th June 2019.
Book your room for the PDA Group Rate.

Single Room € 169 per night* 
Double Room € 194 per night*

*Rates are per room and night, including the following services and benefits free of charge:

  • Buffet Breakfast in the restaurant
  • Wireless Internet Connection (WI-FI)
  • VAT, Taxes and Service will apply

Sponsorship and Exhibit Opportunities are Available!

For more information about exhibit and sponsorship opportunities, please contact:

Nadjeschda Gomez-Stahl
Manager Exhibition & Sponsorship
Tel: +49 (0) 30 43 655 08-23
Fax: +49 (0) 30 43 655 08-66

Register Now