BacterialCountBioburdenChecker

Bacterial Count Bioburden

Vet veterinary veterinary vaccines animal health adjuvants aquaculture batch release CSV→JSON
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Utility description: Bacterial Count Bioburden

Bacterial Count Bioburden Checker — Control of Microbial Bioburden

ℹ️  Utility assesses the level of microbial bioburden in non-sterile pharmaceutical products according to Ph. Eur. 2.6.12 and USP <61>:
     • TAMC (Total Aerobic Microbial Count): Total number of aerobic bacteria.
     • TYMC (Total Yeasts and Molds Count): Total number of yeasts and molds.
     • Recovery Efficiency: Confirmation that the method allows detection of microorganisms present in the product.
     • Incubation Conditions: Strict control of culture growth time.

⚠️  CRITICAL: 
     • Exceeding established limits (e.g., 100 CFU/g for TAMC) indicates unsatisfactory raw material quality or hygiene violations in production.
     • Recovery efficiency below 50% means the method is unsuitable for this product without modification (neutralization of antimicrobial properties).

Usage:
  BacterialCountBioburdenChecker.exe                            → demo mode (console output)
  BacterialCountBioburdenChecker.exe input.csv output.json      → evaluate your data

Input format:
BatchNumber,ProductName,TAMC_CFU_per_unit,TYMC_CFU_per_unit,SampleWeight_g,DilutionFactor,IncubationDays_TAMC,IncubationDays_TYMC,RecoveryEfficiency_Percent

Example:
  BB-001,Cream,50.0,10.0,1.0,10.0,3,5,85.0

— WHY IS THIS NEEDED?
Bioburden control is necessary to ensure microbiological quality of non-sterile products.
High levels of microorganisms can lead to product spoilage, reduced preservative efficacy, and patient health risks.
Results are also used for validation of sterilization processes (if the product undergoes terminal sterilization).

⚠️  CRITICAL:
• Limits depend on route of administration and product type (oral, topical, rectal, etc.).
• Membrane filtration method is preferred for products with antimicrobial activity.
• Neutralization: If product contains preservatives, neutralizers must be used in the culture medium.
• Incubation: TAMC is incubated at 30-35°C (3-5 days), TYMC at 20-25°C (5-7 days).

Key features:
• Verification of compliance with TAMC and TYMC limits
• Method validity control via recovery efficiency
• Incubation condition check
• Generation of reports for microbiology lab and LIMS LabWare
• Compliance with GMP and Pharmacopoeia requirements

Critical parameters:
• TAMC: ≤ 100 CFU/g (for topical products)
• TYMC: ≤ 10 CFU/g (for topical products)
• Recovery Efficiency: ≥ 50%
• TAMC Incubation Days: 3–5
• TYMC Incubation Days: 5–7

💡 Usage tips:
1. Sampling: Must be representative and performed aseptically.
2. Homogenization: Thoroughly homogenize sample with diluent to release microorganisms.
3. Colony Counting: Use only plates with colony counts between 10 and 300 (or up to 250 per USP) for accuracy.
4. Interpretation: If growth is too abundant (TNTC), repeat test with higher dilution.
5. Trends: Analyze bioburden data dynamically for early detection of production process issues.

⚠️ Note: Bioburden is an indicator of process "cleanliness" before sterilization or final control. For non-sterile products, it is one of the main release criteria.

input.csv

BatchNumber,ProductName,TAMC_CFU_per_unit,TYMC_CFU_per_unit,SampleWeight_g,DilutionFactor,IncubationDays_TAMC,IncubationDays_TYMC,RecoveryEfficiency_Percent
BB-2026-CREAM-001,Hydrocortisone Cream,50.0,10.0,1.0,10.0,3,5,85.0
BB-2026-SYRUP-002,Cough Syrup,20.0,5.0,10.0,1.0,4,6,90.0
BB-2026-FAIL-003,Herbal Powder,150.0,25.0,1.0,100.0,3,5,40.0

URS & FS — User Requirements and Functional Specification

This document describes the controlled interface and behaviour of BacterialCountBioburdenChecker for Bacterial Count Bioburden Checker.

Domain limits and critical parameters

Key fragments from the source description are shown below. Before production use, limits must be verified against the approved specification, registration dossier and local SOPs.
  • ℹ️ Utility assesses the level of microbial bioburden in non-sterile pharmaceutical products according to Ph. Eur. 2.6.12 and USP <61>:
  • ⚠️ CRITICAL:
  • • Exceeding established limits (e.g., 100 CFU/g for TAMC) indicates unsatisfactory raw material quality or hygiene violations in production.
  • • Limits depend on route of administration and product type (oral, topical, rectal, etc.).
  • • Neutralization: If product contains preservatives, neutralizers must be used in the culture medium.
  • • Verification of compliance with TAMC and TYMC limits
  • • Compliance with GMP and Pharmacopoeia requirements
  • Critical parameters:
  • • TAMC: ≤ 100 CFU/g (for topical products)
  • • TYMC: ≤ 10 CFU/g (for topical products)
  • • Recovery Efficiency: ≥ 50%
  • 1. Sampling: Must be representative and performed aseptically.
  • 3. Colony Counting: Use only plates with colony counts between 10 and 300 (or up to 250 per USP) for accuracy.

URS — User Requirements Specification

IDRequirementCriticalityAcceptance criterion
URS-001The utility shall accept an input.csv file for Bacterial Count Bioburden Checker with headers defined in the data contract.HighThe file is processed without manual header editing.
URS-002The utility shall perform deterministic QC evaluation without machine learning and without probabilistic conformance decisions.HighIdentical input data, rule version and configuration produce reproducible results.
URS-003The utility shall validate mandatory fields, data types, ranges, units and domain plausibility.HighSchema, conversion and range errors are explicitly reported.
URS-004The utility shall apply domain limits and rules from the description, approved specification, registration dossier and local SOPs.HighEach check has PASS/WARNING/FAIL and a clear message.
URS-005The utility shall generate output.json with machine-readable results, source values, warnings, failures and critical findings.HighJSON is suitable for LIMS/ELN/MES integration and QA/QC review.
URS-006The utility shall preserve traceability between batch/sample, input file, applied rules and final status.HighOutput contains identifiers, checked parameters and audit metadata.
URS-007The documentation shall support IQ/OQ/PQ, CSV/CSA and review by internal QA or inspectors.MediumURS, FS, input/output contract and test scenarios are supplied with the utility.
URS-008The utility shall be used as a QC decision-support tool and not as a substitute for approved specifications and QA/QP release decision.MediumDocumentation states change control and limit-verification expectations.

input.csv contract

#FieldTypeSamplePurpose
1BatchNumberstring / controlled vocabularyBB-2026-CREAM-001Batch or lot identifier used for traceability.
2ProductNamestring / controlled vocabularyHydrocortisone CreamProduct or dosage-form name under evaluation.
3TAMC_CFU_per_unitstring / controlled vocabulary50.0Count parameter used for microbiological, particulate or cellular control.
4TYMC_CFU_per_unitstring / controlled vocabulary10.0Count parameter used for microbiological, particulate or cellular control.
5SampleWeight_gstring / controlled vocabulary1.0Sample or laboratory specimen identifier.
6DilutionFactordecimal10.0Controlled input parameter for deterministic QC rules.
7IncubationDays_TAMCinteger / decimal3Time parameter for process, incubation, storage or analytical workflow.
8IncubationDays_TYMCinteger / decimal5Time parameter for process, incubation, storage or analytical workflow.
9RecoveryEfficiency_Percentdecimal85.0Recovery; indicator of analytical validity.
BatchNumber,ProductName,TAMC_CFU_per_unit,TYMC_CFU_per_unit,SampleWeight_g,DilutionFactor,IncubationDays_TAMC,IncubationDays_TYMC,RecoveryEfficiency_Percent
BB-2026-CREAM-001,Hydrocortisone Cream,50.0,10.0,1.0,10.0,3,5,85.0
BB-2026-SYRUP-002,Cough Syrup,20.0,5.0,10.0,1.0,4,6,90.0
BB-2026-FAIL-003,Herbal Powder,150.0,25.0,1.0,100.0,3,5,40.0

Input validation rules

IDFieldRuleCriticality
VR-001BatchNumberThe field shall match an approved dictionary or accepted string representation.High
VR-002ProductNameThe field shall match an approved dictionary or accepted string representation.High
VR-003TAMC_CFU_per_unitThe field shall match an approved dictionary or accepted string representation.High
VR-004TYMC_CFU_per_unitThe field shall match an approved dictionary or accepted string representation.Medium
VR-005SampleWeight_gThe field shall match an approved dictionary or accepted string representation.Medium
VR-006DilutionFactorThe field shall match an approved dictionary or accepted string representation.Medium
VR-007IncubationDays_TAMCThe field shall match an approved dictionary or accepted string representation.Medium
VR-008IncubationDays_TYMCThe field shall match an approved dictionary or accepted string representation.Medium
VR-009RecoveryEfficiency_PercentThe field shall match an approved dictionary or accepted string representation.Medium

FS — Functional Specification

IDFunctionImplementation
FS-001CLI executionSupport execution modes: demo mode without arguments and production mode input.csv output.json.
FS-002CSV importRead input.csv in UTF-8/CSV-compatible format and validate header and expected columns.
FS-003Schema validationCheck mandatory fields, column count, unknown key fields and empty mandatory values.
FS-004Type conversionConvert numeric, flag and text values; invalid format is recorded as a row-level error.
FS-005Domain rule engineApply rules for Bacterial Count Bioburden Checker, including critical limits from the description and approved specification.
FS-006Status aggregationProduce final status: FAIL for critical failure, WARNING for non-critical deviation, PASS for conformance.
FS-007JSON exportWrite output.json with detailed checks, source values, warnings, failures and critical findings.
FS-008Audit supportKeep result structure suitable for review, deviation investigation and calculation reproduction.
FS-009Integration contractSupport the scenario LIMS/ELN/MES → input.csv → utility → output.json → portal/admin review.
FS-010Error handlingReturn explicit messages for missing file, empty CSV, invalid schema, output write failure and invalid format.

Example output.json

{
  "utilityId": "bacterialcountbioburdenchecker",
  "utilityFolder": "BacterialCountBioburdenChecker",
  "package": "Vet",
  "overallStatus": "PASS|WARNING|FAIL",
  "sourceFile": "input.csv",
  "processedAtUtc": "2026-06-10T00:00:00Z",
  "checks": [
    {
      "parameter": "BatchNumber",
      "value": "BB-2026-CREAM-001",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-001"
    },
    {
      "parameter": "ProductName",
      "value": "Hydrocortisone Cream",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-002"
    },
    {
      "parameter": "TAMC_CFU_per_unit",
      "value": "50.0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-003"
    },
    {
      "parameter": "TYMC_CFU_per_unit",
      "value": "10.0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-004"
    },
    {
      "parameter": "SampleWeight_g",
      "value": "1.0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-005"
    },
    {
      "parameter": "DilutionFactor",
      "value": "10.0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-006"
    },
    {
      "parameter": "IncubationDays_TAMC",
      "value": "3",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-007"
    },
    {
      "parameter": "IncubationDays_TYMC",
      "value": "5",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-008"
    },
    {
      "parameter": "RecoveryEfficiency_Percent",
      "value": "85.0",
      "status": "PASS|WARNING|FAIL",
      "message": "Deterministic rule-based check result",
      "ruleReference": "FS-RULE-009"
    }
  ],
  "criticalFindings": [],
  "warnings": [],
  "audit": {
    "inputHash": "sha256:<calculated at runtime>",
    "rulesVersion": "<utility executable version>",
    "documentation": "BacterialCountBioburdenChecker.documentation.html"
  }
}

Traceability matrix

URSFSTestEvidence
URS-001FS-001, FS-002OQ-001Verify execution and import of valid input.csv.
URS-002FS-005, FS-006OQ-004Repeat the same dataset and compare output.json.
URS-003FS-003, FS-004, FS-010OQ-002, OQ-003Verify missing columns and invalid types.
URS-004FS-005, FS-006OQ-004, PQ-001Verify critical deviations on real/boundary data.
URS-005FS-007, FS-009OQ-005Verify JSON schema and downstream-system suitability.
URS-006FS-008OQ-006Verify identifiers and audit metadata.
URS-007FS-008, FS-010IQ-001, OQ-007Verify documentation completeness and control evidence.
URS-008FS-005, FS-008PQ-002Verify review workflow and no replacement of QA decision.

IQ/OQ/PQ test scenarios

IDScenarioExpected result
IQ-001Verify executable, input.csv, documentation and checksum availability.Delivery set is complete; version is recorded.
OQ-001Valid sample row from input.csv.PASS or acceptable WARNING according to rules.
OQ-002Remove a mandatory CSV column.Schema error or FAIL with missing-column reference.
OQ-003Place a non-numeric value into a numeric field.Type-conversion error with row/field reference.
OQ-004Set a critical parameter outside the limit.FAIL and critical finding.
OQ-005Verify output.json structure.All mandatory sections are present and JSON is valid.
OQ-006Verify batch/sample traceability.Input and result identifiers match.
PQ-001Verify 3–5 real user batches/samples.Result is confirmed by QC/QA review.
PQ-002Verify deviation workflow and manual QA decision.Utility supports review but does not replace approved decision.

QA/QC and change control

  • Do not rename columns without updating validator, documentation and test set.
  • Retain input.csv, output.json, executable version and checksum.
  • Before production use, perform IQ/OQ/PQ or equivalent CSV/CSA verification.
  • Critical limits shall be verified against the approved specification, registration dossier and local SOPs.
  • The utility provides structured QC decision support; final release decision remains with QA/QP and approved procedures.

Included in packages

Infectious Diseases QC Suite

QC utility package for infectious diseases: antibacterial, antiviral, antifungal and antiparasitic products, microbiology, sterility, endotoxins, viral safety and vaccine release checks.

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Vet — Veterinary QC Utilities

Vet is designed for veterinary pharmaceuticals and vaccines: adjuvants, antigens, autogenous vaccines, aquaculture, feed/premixes, antimicrobial and antiparasitic products, sterility and batch release.

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