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Electronic batch record (EBR)

How one batch was made, every step signed.

INSIDE: MANUFACTURING EXECUTION SYSTEM (MES) FOR PHARMAHOW IT WORKS · A BATCH OF 1,20,000 ANTIBIOTIC CAPSULESThe plant copies theapproved masterrecord: 48 stepsMachines andoperators add about900 entries duringthe batchAt step 31, thedrying room reads27°C against a 25°Climit, and the entryis flaggedThe flag is linkedto a deviation,which is investigatedand closedThe reviewer checks 3flagged entries, not900, and releases thebatch the next dayINSIDE: MANUFACTURING EXECUTIONSYSTEM (MES) FOR PHARMAHOW IT WORKS · A BATCH OF1,20,000 ANTIBIOTIC CAPSULESThe plant copies theapproved master record:48 stepsMachines and operatorsadd about 900 entriesduring the batchAt step 31, the dryingroom reads 27°C against a25°C limit, and the entryis flaggedThe flag is linked to adeviation, which isinvestigated and closedThe reviewer checks 3flagged entries, not 900,and releases the batchthe next dayINSIDE: MANUFACTURING EXECUTIONSYSTEM (MES) FOR PHARMA · A BATCHOF 1,20,000 ANTIBIOTIC CAPSULESThe plant copies the approved masterrecord: 48 steps↓Machines and operators add about 900entries during the batch↓At step 31, the drying roomreads 27°C against a 25°Climit, and the entry is flagged↓The flag is linked to a deviation, whichis investigated and closed↓The reviewer checks 3 flaggedentries, not 900, and releasesthe batch the next day
The electronic batch record collects about 900 entries for one batch of 1,20,000 capsules, flags a drying-room reading above its limit, and lets the reviewer release the batch after checking only 3 flagged entries.
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An electronic batch record (EBR) is the official record of how one batch of a medicine was made, kept digitally instead of on paper. It holds every step of the batch, every reading, and the name and signature of the person who did each step. It is also called an e-batch record. The paper version is called a batch manufacturing record, or BMR.

Every medicine has an approved master record. It is the template of steps that every batch must follow. For each new batch, the plant makes a copy of this template. As the batch is made, the operators fill in the copy. In a plant that uses paper, this copy can run to hundreds of pages. Each page is filled in by hand, signed, and checked again by a second person.

Before a batch can be sold, the quality team must review the whole record. This is called batch release. With paper, the reviewer reads every page, looks for missing signatures and recalculates the figures. This often takes several days.

The EBR changes this in two ways. First, the manufacturing execution system (MES) fills in most of the record itself, directly from scales, sensors and barcode scanners. Second, the software checks every entry against its limit as soon as it is made. So the reviewer does not have to read every entry. The reviewer looks only at the entries that the software flagged. This is called review by exception.

Consider a plant in Goa that makes an antibiotic capsule in batches of 1,20,000 capsules. The master record has 48 steps. During the batch, the EBR collects about 900 entries. Most come from machines, with the time and the operator's name. At step 31, the drying room records 27°C, but the limit is 25°C. The EBR flags that entry at once. It links it to a deviation in the quality management system (QMS). The investigation finds that the reading was short and caused no harm. At the end, the quality reviewer looks at only 3 flagged entries and the closed deviation, instead of 900 entries. The batch is released the next day, instead of after five days.

The EBR must be trustworthy for many years. An inspector may ask for it long after the batch was sold. So every entry shows who made it and when. No entry can be deleted. A correction is added as a new entry with a reason, and the old value stays visible. This history is called an audit trail. These rules are described in GxP compliance.

Why does this matter in India? Many Indian plants still use paper records. Regulators such as CDSCO and the US FDA often find problems in records during inspections, such as missing entries or changed figures. An EBR makes these problems harder to create and easier to find. The batch record is the main evidence of pharma manufacturing done correctly.

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