SOP Title: Dispensing of Packing Materials
- Objective:
To lay down the procedure for Dispensing of Packing Material in the Warehouse.
- Scope:
This SOP is applicable for Dispensing of Packing Materials in the Warehouse .
- Responsibility:
- Warehouse: To prepare and review the SOP. To follow the procedures laid down for dispensing of packing materials as per this SOP.
- Packing Department: To share the Batch Packing Record to Warehouse Department one day in advance. To return the excess packing material to Warehouse Department.
- Quality Assurance Department: To review and approve the SOP and Annexure. To verify the respective entries in BPR.
- Accountability:
Head, Warehouse Department and Head, Quality Assurance
- Procedure:
- Definitions:
- Primary Packing Material: Any packing material coming in direct contact with product. E.g.: Alu, PVC, PVDC foils, HDPE containers and likewise.
- Secondary Packing Material: The packing materials required to pack the primary packed product e.g., cartons, PIL’s, Labels and likewise.
- Tertiary Packing Material: The packing material used for transport purpose e.g., cartons, shippers and likewise.
- First in First Out: A chronological sequence for selecting the packing materials for dispensing i.e., material received on earlier date is selected first followed by packing material on later date.
- Excess packing material return: Any unused primary packing material, post packing activity, to be returned to the warehouse by the production department with a suitable label. Warehouse to do the required entry and inward the material.
- Disinfectant solution: Prepared by addition of 2.5 ml of Savlon in 100 ml of purified water. To be prepared and used freshly and not to be stored
- Definitions:
- Procedure:
| 5.2.1 | Receive the BPR containing the BOM from the packing department. | |
| 5.2.2 | Before starting dispensing operation ensure the following checks
a. Cleanliness status label of the area b. Temperature and humidity compliance c. Status board entry d. PPE availability and usage e. All materials have ‘Approved labels’ f. Calibration status of the balances |
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| 5.2.3 | Collect the required boxes of the Packing materials as per BPR, from the respective racks
Note: Check the presence of packing materials with the ‘Material Return Label’. Check for the product name and if the label matches, use these batch number materials for dispensing in preference over other available batch number materials. |
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| 5.2.4 | The Packing material should be dispensed on First In First Out basis. | |
| 5.2.5 | Re-check the Materials with the BOM mentioned in the BPR before starting the dispensing activity | |
| 5.3 | Dispensing of Primary Packing Materials | |
| 5.3.1 | Place the required foil along with the polybag and record the weight in BPR. If the selected foil quantity is lesser than the quantity mentioned in BPR, then Dispense additional complete rolls of desired foil which will be more than the quantity as per BPR. Record in BPR the actual quantity dispensed.
If the selected foil quantity is higher than the quantity mentioned in BPR then Dispense the higher quantity. Record in BPR the actual quantity dispensed. |
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| 5.3.2 | Label the dispensed materials for ‘Packing Material Dispensing Label’ alongside the ‘Approved Label’ as per Annexure. | |
| 5.3. 3 | Transfer the dispensed primary packing material in a S.S cage. Label the SS cage as per Annexure. | |
| 5.3.4 | Enter the details in ‘Packing Material Dispensing Log Book’ . | |
| 5.4 | Dispensing of Secondary Packing Material – Labels and PIL | |
| 5.4.1 | Count 100 labels or PIL and record the weight in BPR. Calculate the target weight needed for desired count of labels as per BPR. | |
| 5.4.2 | Dispense labels or PIL as per the target weight calculated and record the count and weight in BPR. | |
| 5.4.3 | Transfer the dispensed labels or PIL with clean double polybag. Label the dispensed materials for ‘Packing Material Dispensing Label’. | |
| 5.4.4 | Transfer the dispensed labels or PIL in a S.S cage. Label the SS cage as per Annexure. | |
| 5.4.5 | Enter the details in ‘Packing Material Dispensing Log Book’. | |
| 5.5 | Dispensing of Secondary Packing Material – Cartons | |
| 5.5.1 | Count the cartons in one bundle and record the count in BPR. Calculate the target bundles needed for desired count of cartons as per BPR. | |
| 5.5.2 | Dispense carton bundles as per the target count calculated and record the count in BPR. | |
| 5.5.3 | Transfer the dispensed carton bundles in clean plastic bins. Label the dispensed materials with ‘Packing Material Dispensing Label’ as per Annexure. | |
| 5.5.4 | Transfer the plastic bins in a S.S cage. Label the SS cage as per Annexure. | |
| 5.5.5 | Enter the details in ‘Packing Material Dispensing Log Book’. | |
| 5.6 | Dispensing of Tertiary Packing Material | |
| 5.6.1 | Count the shippers, printed BOPP tapes, cartons and likewise as mentioned in BPR. | |
| 5.6.2 | Dispense shippers, printed BOPP tapes, cartons and likewise and record the respective counts in BPR. | |
| 5.6.3 | Transfer the tertiary packing materials in clean plastic bins. Label the dispensed materials with ‘Packing Material Dispensing Label’ as per Annexure. | |
| 5.6.4 | Transfer the plastic bins in a S.S cage. Label the SS cage as per Annexure. | |
| 5.6.5 | Enter the details in ‘Packing Material Dispensing Log Book’. | |
| 5.7 | Return of excess primary packing material from packing department | |
| 5.7.1 | Any excess primary packing material should be received from the packing department along with a ‘Material Return Label’. Enter the details in software. | |
| 5.7.2 | Place the excess primary packing material in a polybag and shift to the designated rack of the packing material warehouse | |
| 5.8 | Dispensing of additional packing material from packing department | |
| 5.8.1 | Any additional quantity of packing material other than the quantities mentioned in BPR, if required by packing department, should be submitted through a requisition, ‘Excess Material Requisition Note’. | |
| 5.8.2 | Refer steps number 5.3, 5.4, 5.5 or 5.6 based on the type of packing material required | |
| 5.9 | Cleaning | |
| 5.9.1 | Remove any threads, seals, polybags, any residual packing materials present in the area | |
| 5.9.2 | Mop the floor area with disinfectant solution. (i.e. 2.5% v/v Savlon in purified water) | |
| 5.9.3 | Clean all Plastic Bins and S.S. cage with the help of vacuum cleaner and wipe with a lint free duster moistened with purified water. |
- Abbreviation
| Abbreviation | Expansion |
| BOM | Bill Of Materials |
| WHD | Warehouse Department |
| SS | Stainless Steel |
| % | Percentage |
| PVC | Polyvinyl Chloride |
| PVDC | Poly vinyl Di chloride |
| Alu | Aluminium |
| HDPE | High Density Poly Ethylene |
| PIL | Patient Information Leaflet. |
*Note – Ready to use SOP available in “DOWNLOAD” Section.