Case Study: Remediation of Aseptic Operations — Oversight, EM, and Sterility Assurance Redesign

Case Study Overview

Sterility assurance remediation in sterile biologics manufacturing is one of the most critical challenges for vaccine and injectable drug producers. When aseptic operations fall short of Annex 1 requirements, the risks extend beyond compliance — threatening patient safety, regulatory approval, and supply continuity. This case study shows how GMP Bridge supported a DACH-based biologics manufacturer to redesign its Contamination Control Strategy (CCS), optimize Environmental Monitoring (EM), and strengthen Quality Oversight, ensuring sustainable compliance and restored client confidence.

The Challenge

A sterile biologics manufacturer in the DACH region faced significant sterility assurance risks after repeated client complaints and regulatory observations. The site’s aseptic operations were considered non-compliant, with gaps in oversight, contamination control, and environmental monitoring practices threatening supply continuity and regulatory trust.

Quick Summary

Region: DACH (Germany, Austria, Switzerland)
Company Type: Single-site sterile biologics manufacturer
Products: Vaccines and sterile injectable drug products

Solution Delivered

Conducted a comprehensive gap assessment of CCS, EM programs, and sterility assurance measures.
Designed a new integrated Contamination Control Strategy (CCS) supported by a Contamination Control Risk Assessment (CCRA).
Redesigned EM strategy with improved sampling plans, alert/action levels, and trending practices.
Established a formal Quality Oversight Program covering aseptic manufacturing.
Revised gowning, material transfer, and aseptic behavior qualification and practices.
Delivered hands-on training and coaching for QA and production teams.

Impact and Results

Client confidence restored and supply interruptions avoided.
Successfully passed a regulatory audit post-remediation.
Sterility assurance risks identified and mitigated with risk-based actions.
Improved ownership and accountability through structured oversight.
Reduced deviation rates and improved aseptic shop-floor practices.

Facing sterility assurance risks or regulatory findings?