A former epidemic official said, because of the epidemic, most auditors drew their conclusions from documents and video tours during which Emergent activists controlled camera angles.
Auditors of Johnson & Johnson said surveillance reports for bacteria or other contaminants were filed four to six months late. AstraZeneca said that Emergent repeatedly loosened surveillance norms, so it appeared to meet them, resorting to measures of “historical precedent”. But even then the test failed, the report said.
In another audit, BARDA officials documented similar concerns, classifying some of them as “significant” along with the risks of microbiological contamination. This designation is reserved for the most serious problems that pose an immediate and significant risk.
Emergent’s own internal audit in July also stated that the flow of workers and materials through the plant was not adequately controlled “to prevent mix-up or contamination”.
Echoing quality-control deficiencies reported by FDA in an April inspection First reported by Associated Press, That concluded that the facility was “not ready for commercial operation.”
Multiple audits underline how bad the company was for the huge workload it had accepted.
The Covid-19 projects required more testing to keep the content stable, but Emergent had just one employee coordinating it, the BARDA audit found. Emergent acknowledged at the time that its testing system was “not ideal” and pledged to train at least one more Emergent worker and appoint a third. BARDA did not respond to requests for comment on its audit or any other, saying it had “worked with Emergent” to resolve issues raised during the FDA inspection.
Another internal investigation in August found that Amergent approved four of the raw materials used to use AstraZeneca’s vaccine, without being fully tested first. This type of shortcut, called the conditional release of content, occurs an average of twice a week in October, internal log shows. The measure that was deemed necessary because the company was dealing with the short production time, test backlog, and operation-wise speed, the needs of the Trump administration’s crash vaccine development program. While one manager “intentionally deviated” from the standards, the report said, vaccine batches would not be released without quality and safety tests.