Production Sterile - Packing Operator

USV PRIVATE LIMITED; Daman; On-site; INR 250,000 - 450,000; Full time

Job summary

USV PRIVATE LIMITED is seeking a skilled operator to manage sterile packaging lines for injectable products in our Daman facility. You will set up and run machines for vials, ampoules, and pre-filled syringes, ensuring compliance with BPR and regulatory standards.

Responsibilities include online aseptic/visual inspections, line clearance during changeovers, leak testing, material handling, and meticulous logbook entries to support ALCOA+ data integrity.

Responsibilities

• Set up, assemble, and operate sterile packaging machinery for injectables (vials, ampoules, pre-filled syringes, BFS/FFS) per BPR.
• Perform online visual inspection for clarity, particulates, container integrity, volume, and sealing defects.
• Execute area cleaning, sanitation, and line clearance protocols during product changeovers to prevent cross-contamination.
• Conduct in-process seal integrity testing and track checks for cap crimping or ampoule sealing.
• Receive, verify batch details, and load primary/secondary materials under controlled packaging environment standards.
• Record machine operating data, downtime, rejected quantities, and room conditions in Batch Packing Records and equipment logbooks adhering to ALCOA+.
• Identify minor mechanical or pneumatic faults and assist maintenance with changeovers.
• Calculate and reconcile used, unused, and rejected packaging components to ensure accurate batch material balances.
• Keep the sterile packing suite, machine surfaces, and documentation organized, clean, and ready for regulatory inspections (USFDA, EU Annex 1, WHO).
• Adhere to cleanroom zoning, wear PPE, maintain personal hygiene, and uphold 5S discipline.

Job description

• Sterile Packing Machine Operation: Set up, assemble, and operate primary and secondary packaging machinery for injectables (vials, ampoules, pre-filled syringes, BFS/FFS) in compliance with BPR specifications.
• Aseptic & Visual Inspection: Perform online visual inspection (or monitor automated inspection systems) for clarity, particulate matter, container integrity, volume levels, and sealing defects.
• Line Clearance Execution: Execute thorough area cleaning, equipment sanitation, and line clearance protocols (Type A/B) during product changeovers to prevent cross-contamination or line mix-ups.
• Leak & Seal Testing: Conduct routine in-process seal integrity testing (dye ingress, high-voltage leak detection, vacuum decay) and track parameter checks for aluminum cap crimping or ampoule sealing.
• Packaging Material Handling: Receive, verify batch details, and load primary/secondary materials (aluminum caps, trays, cartons, leaflets, outer shippers) under controlled packaging environment standards.
• Logbook & BPR Entries: Record real-time machine operating data, downtime, rejected quantities, and room conditions in Batch Packing Records (BPR) and equipment logbooks adhering to ALCOA+ rules.
• Troubleshooting & Maintenance: Identify minor mechanical or pneumatic machine faults during operations (e.g., optical sensor misalignment, star-wheel jams) and assist maintenance technicians with changeovers.
• Material Yield & Reconciliation: Calculate and reconcile used, unused, and rejected packaging components at the end of each shift to ensure accurate batch material balances.
• Audit & Cleanroom Compliance: Keep the sterile packing suite, machine surfaces, and documentation organized, clean, and ready for internal and external regulatory inspections (USFDA, EU Annex 1, WHO).
• EHS & Cleanroom Hygiene: Adhere to cleanroom zoning guidelines, wear mandatory personal protective equipment (PPE), follow strict personal hygiene standards, and maintain workplace 5S discipline.