QA/QC

In house laboratory testing available:

• GC-FID, GC-TCD (purity, blend accuracy)
• Density, specific gravity (lb./gal. Cup or hydrometer) - ASTM D 891
• Karl Fischer water testing - ASTM D 1744
• Viscosity (Brookfield)
• Refractive Index - ASTM D 1218
• % Solids (loss @ 1050 C)
• Flash Point (Tag closed cup)
• pH
• Various titrametric methods
• Develop QC analytical procedures (SOPs) specific to product or customer as required
• Test product batches prior to filling. When approved, mark with appropriate labels
• Where intermediate storage is utilized, product in each container is re-tested for approval and marked before releasing to filling line

Line sample checks - start, middle, end run:

• Product quality (GC or other testing)
• Container and box labeling and codes (visual inspection for accuracy and placement)
• Fill level and fill weight (visual and scale wt.)
• Proper tightening/sealing of caps and seals (visual check and/or manual testing)
• Box inserts added (e.g. MSDS), box properly filled & closed/taped
• Retain blending and filling samples for required time
• Maintain batch/filling/analytical records and retain for required time
• Provide quality Certifications of Analysis or Compliance as required
• Assist customer in development of product specifications

 
CONCERNS/SOLUTIONS

Wrong product filled

• Each storage container sampled, tested, and marked with product name, lot number and approval sticker.
• Filling line personnel check each container for correct product name, lot number 
  and approval sticker before moving to filling area
• QC line sample checks for product ID/quality, container fill weight
• Old stickers removed from empty containers
• Dedicated, labeled and sealed product storage

Wrong product label
Wrong bar code/batch number
Unmatched product label and bar code on can or box

• Proper can and box labels set aside for each order
• Bar code stickers with batch numbers run and set aside with product labels - 
  correct amount for each batch
• Each batch-boxes, cans-labeled immediately prior to filling
• Pallets of cans and boxes checked prior to filling
• QC line checks on labels and bar code stickers

Under/over fills

• All product containers filled to documented specification fill limits
• QC line checks on container weights, documented
• Fill weight specifications documented and on work orders used by filling line personnel

Batch uniformity - Batch size - Batch tracking

• Run batch on campaign basis - run until entire batch is packaged
• Batch size based on existing orders and product forecast
• Large volume blends will be broken down to multiple (smaller) batches, each separately tested and numbered
• Boxes coded by batch and date. Cans coded by batch, date, fill sequence

Standard Operating Procedure application and implementation

• Documentation - general SOPs for filling and other SOPs specific to product or customer
• Documents for work orders, product specification, on-line QC checks available and utilized