Batch Packaging Record -Product Name___________

Document No.: BPR- Replaces: Nil Page 1 of 13

Issue Date: 02-07-2020 Effective Date: 02-07-2020 Revision Date:02-07-2023
Department/Section: Production Shelf life: Registration No:
Batch No.: Batch Size:
Manufacturing Date: Expiry Date:

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PACKAGING INSTRUCTIONS
1. Receive all packaging materials from warehouse as per SOP # (CCL-SOP-1211).
2. All packaging materials and product of the previous batch must be removed from the machine and
packaging line.
3. Perform the over printing, blistering & packaging "LINE CLEARANCE" according to SOP # (CCL-
SOP- 1140) to make sure that previous batch has been removed from the machine and packaging
line. (In some cases, online printing will be done, as required.)
4. Bring the Product & Packing material to the blistering & Packing line along with their respective
BPR, Move order, Packaging work order.
5. At the work station, DISPLAY the information about Product Name, Batch No., Batch Size, Stage
and Date, of the running Product.
6. Perform blistering / packaging process as per SOP # (CCL-SOP-1216). Check each filled blister for
its Batch No., Expiry Date, No. of tablets, leakage test and Physical Appearance.
7. Check each unit carton for Batch no., Mfg. Date, Exp. Date, Price, Physical appearance and Text as
per SOP # (CCL-SOP-1216).
8. Collect rejected cartons and blisters in poly bags labeled with "Rejected" label.
9. Weigh each blister (Alu-Alu) & packed unit with Balance for its content verification as per SOP #
(CCL-SOP-1216).
10. Visually inspect each blister (Alu-PVC) & weigh packed unit with Balance for its content
verification as per SOP # (CCL-SOP-1216).
11. Note the tare weight of each Outer Carton.
[Outer Carton type (________________)]
Placement of unit cartons in Outer Carton:
(________lines x _______packs) +_______packs on side = __________ No. of units packed in
Outer Carton.
Seal the Outer Carton with CCL Logo PVC tape and then paste outer sticker (O/S) on it.
12. Before sealing each Outer Carton, final packer must 100% physically check the no. of units present,
and after sealing the Outer Carton, note down the gross weight on it and sign properly in such a way
that it covers both the flaps of Outer Carton.
13. Check each outer sticker (O/S) before pasting it on each sealed Outer Carton for its Product Name,
Batch No., Mfg. Date, Exp. Date, Quantity of units and numbering of outer cartons.
14. Production officer must randomly check the sealed outer cartons (C/BOX) for its content
verification.
15. If the last outer Carton (Loose packs) is partially packed on the completion of batch then get it signed
by the production officer for its quantity verification and QA also verify loose packed outer Carton.
16. Weigh each outer carton with weighing balance to verify its contents. Make the report of weighing

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 verification, dully signed by Production officer & QA officer & attach in BPR.
17. Arrange each Outer Carton properly on the pallet.
18. After completion of batch, make the finish transfer note & also enter the no. of finished units into
oracle system.
19. Return unused materials to Warehouse on return format as per SOP # (CCL-SOP-1278).(if
required)
20. Get all Batch related documents (MP, Packaging move order, reconciliation report, yields report,
return to store & FG transfer move order) from oracle & attach in BPR.
21. Complete the Packaging document and get it signed by Production officer & send the document to
Quality Assurance for the final release of the product.
All the packaging instructions have been read and understood.

Operator / Line In-charge Production Officer QA Officer

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 PROCESS FLOW CHART
Step 1: Packaging Material Received from Step 2: Bulk material received from production
Warehouse and transfer to Blistering area
 Unit Cartons  Aluminium base foil /
PVC / PVDC
 Printed Alu Foil  Labels
 Printed PVC Tape  Outer Cartons
 Literature

Step 1(a): Over-Printing Step 2(a): Blistering operation

Over-printing of Unit Cartons and physically checking Carry out the blistering operation by setting of
them for appropriate over-printing. foils and machine.

In-process checks:
 Leakage
 Embossing
 Physical
Appearance

Step 3: Packaging Operations:

After checking blisters physically (for Alu-PVC), pack
them in unit cartons manually with literature enclosed.

Step 4:
Weigh each blister ( Alu-Alu / Alu-tropical ) and visually
inspect Alu-PVC Blisters.
Pack them in unit cartons and then place in outer cartons /
shippers after weighing.

Step 8:
Step 5: Transfer the released stock to transit
Properly label the outer cartons/shippers, weigh and warehouse
place them on designated pellets.

Step 6: Reconciliation of packaging materials/batch Step 7: Intimate QA for stock release

yield

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PRODUCT RELEASE SLIP FOR BLISTERING OPERATION:

Attach Product Release Slip Here

Machine Deployment
Production
Machine Code Capacity Remarks QA Officer
Officer

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LINE CLEARANCE:
Perform Line Clearance as per SOP # (CCL-SOP-1140) on respective Line Clearance form.

Attach Line Clearance Form Here

Status
CHECKLIST:
Yes No
Line Clearance for Over Printing
Line Clearance for Blistering
Line Clearance for Packaging
Line Clearance for Sorting

INSTRUCTIONS FOR BLISTERING OPERATION:

Line clearance as per SOP (CCL-SOP-1140).
Perform leakage test in start of blistering operation, after any break and shift change over.

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CRITICAL PROCESS PARAMETERS OF BLISTERING MACHINE :

Critical Process Parameters

Tick Machine Names &
Here Codes Forming Digit Embossing Sealing Tropical
heater Temp. plate Temp. heater Temp. Heater Temp.
Automatic Blister
Packing Machine Nil Nil 140 to 170 C Nil
(M 548)
Automatic Blister
Packing Machine Nil Nil Nil Nil
(M 540)
Automatic Blister
Packing Machine 80 to 110 ◦C Nil 130 to 160 ◦C 140 to 170 ◦C
(M 539)
High Speed
Automatic Blister 100 to 150 ◦C 90 to 120 ◦C 125 to 160 ◦C Nil
Machine (M 552)

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IN-PROCESS CONTROL SHEETS:

Attach in-process control sheets Here

Status
CHECKLIST:
Yes No
In-Process Control Sheets for Over Printing Monitoring
In-Process Control Sheets for Blistering
In-Process Control Sheets for Packaging

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TEAM LAYOUT SHEETS:

Attach team layout sheets Here

Status
CHECKLIST:
Yes No
Team Layout Sheets for Over Printing
Team Layout Sheets for Blistering
Team Layout Sheets for Packaging

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INSTRUCTIONS FOR PACKING OPERATION:
 Line clearance:
 Weighing balance calibration
 Physical checking of blisters, Unit cartons & literature
 Weighing of blisters
 Weighing of shippers before packing and after packing on shipper verification form.
 Checking of outer label over printing

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PACKING WORK ORDER AND RECONCILIATION:

Attach Packing Work Order And Reconciliation Here

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ORACLE RECONCILIATION AND MATERIAL TRANSFER SHEET:

Attach Oracle Reconciliation And Material Transfer Sheet Here

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FINISHED GOOD TRANSFER NOTE AND ORACLE FG TRANSFER NOTE

Attach finished good transfer note and oracle FG transfer note Here

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