FDA Warning Letter: Jabil sterile manufacturing deficiencies involving fungal contamination and quality oversight

What happened

FDA’s February 23 to March 6, 2026, inspection of Pharmaceutics International, Inc., a Jabil company and contract manufacturer of sterile injectables, identified significant finished-pharmaceutical CGMP violations. FDA found inadequate investigations of a sterility failure involving Ustilago spermophora and recurring fungal recoveries in Grade A filling areas, including insufficient root-cause analysis, trend evaluation, and CAPA. The quality unit did not ensure complete documentation of aseptic interventions; one batch record documented 12 interventions although records indicated approximately 200 occurred. FDA also cited inadequate disinfectant efficacy studies and failure to perform process validation after adding a production step. Airflow visualization studies were deficient or omitted following RABS modifications, and some interventions lacked adequate smoke visualization. Environmental monitoring used insufficient sampling techniques and locations. Classified areas also had peeling paint and plastic debris. FDA considered the company’s responses inadequate because they did not sufficiently address contamination sources, systemic investigation weaknesses, quality oversight, or sustainable remediation.

Why it matters

From a sterile manufacturing perspective, recurring fungi, incomplete intervention records, deficient smoke studies, and weak environmental sampling may limit the ability to identify contamination routes and assess whether exposed sterile product remained protected. Inadequate investigations and CAPA may allow adverse trends or root causes to persist. Weak quality-unit oversight, missing process validation, insufficient disinfectant studies, and deteriorating classified-area surfaces may also undermine evidence that aseptic operations remain reproducible and in a continued state of control.

Key topics: Inadequate investigation of sterility failure and recurring Grade A fungal recoveries, Incomplete aseptic intervention records and deficient quality unit oversight, Deficient airflow studies, environmental monitoring, and classified-area maintenance

Source: U.S. Food and Drug Administration (FDA)