Bar Sealer Operational Qualification Protocol
Use the A.P. Lyon Bar Sealer Operational Qualification (OQ) Protocol to plan and document challenges to the proposed sealing process limits for medical-device sterile-barrier packaging. The editable format provides a structured starting point for bar sealing of pouches.
Included: one editable Microsoft Word (.docx) protocol, supplied in a ZIP file as a digital download.
Bar sealer operating-window qualification
Prerequisite checks for installation qualification, calibration, procedures and personnel training.
Risk-management records linking packaging and process controls to verification evidence.
Challenges at the upper and lower limits of the proposed operating window, with a documented rationale.
Test setup and observation records for seal strength, visual inspection and applicable dye penetration.
Sample traceability, results, deviations and review/approval documentation.
Before execution, customize and approve the equipment, materials, product-family coverage, process limits, sampling rationale, laboratory methods and acceptance criteria. Example quantities and limits require justification for your application. This is an editable document; qualification depends on your approved study and results.
The revised document addresses ISO 11607-1:2019 and ISO 11607-2:2019, each with Amendment 1:2023. Applicable test sections address ASTM F88/F88M-23 seal strength, ASTM F1886/F1886M-25 visual inspection and ASTM F1929-23 dye penetration for suitable porous/transparent seal constructions.
The revised protocol also references EN 868-5, ISO 13485:2016 and FDA QMSR (21 CFR Part 820).
After defining and challenging the proposed operating window, evaluate repeatable production performance with the Bar Sealer Performance Qualification Protocol. Both protocols are included in the Bar Sealer Qualification Protocol Bundle.
Using an eQMS? These editable Microsoft Office files can be imported into any electronic quality management system (eQMS) that manages Word and Excel documents, or used in a paper-based system. Adapt the approval, signature and record steps to your system’s workflow, and validate the eQMS software under your own QMS. See how to use A.P. Lyon procedures in an eQMS.
Practical guide
Read Bar Sealer Qualification: Planning Pouch OQ and PQ for workflow guidance, a checklist and common mistakes.
