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VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Company Name
Date of Purchasing:
Date of Installation:
Model number:
Capacity:
Operator Name:
Department (Place)
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Table of Contents
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Humidification: -..................................................................................................................... 17
Gas injection and gas dwell: -................................................................................................17
Post exposure gas purge and air in bleed: -...........................................................................18
Heated aeration: -.................................................................................................................. 18
Appendix 1 Simulation of Anticipated Process Conditions.........................................................21
Appendix 2:- Determination of Bioburden..................................................................................22
Determination of Bioburden.......................................................................................................22
Appendix 3(GLOSSARY)........................................................................................................... 23
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
The Validation Protocol shall be Prepared, Reviewed and Approved by the concerned
personnel. It shall be signed and dated as shown below.
Prepared by:
Checked by:
Approved by:
2. REVISION HISTORY
REASON FOR
REVISION REVISION DATE REVISION/CHANGE REVISED BY
REQUEST
01 Original release
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
3. OBJECTIVE:-
4. SCOPE:-
The scope of validation protocol is to provide sterilization validation strategies for ethylene oxide
sterilization of medical device. This document will show two approaches for reducing or
eliminating bioburden on medical devices. This will also show test method, sampling method
and acceptance criteria used in validating ethylene oxide sterilization of medical devices.
5. RESPONSIBILITY:-
Person Responsibility
Validation team Preparation of protocol
Organization of validation activity
Collecting the samples and sending to QC
Review and interpretation of final results
Preparation of report
Quality control Review of protocol and report
Analyzing the test samples
Reporting and interpretation of results
Production Review of protocol and report
Conducting the validation activity as per the protocol
Quality assurance manager Review and approve the validation protocol
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
7. LIST OF DOCUMENTS:-
8. PRE-REQUISITE:-
The following requisite must be fulfilled before the ethylene oxide sterilization process validation.
Equipment qualification:-
Product qualification:-
Product and packaging material evaluation: - As per ISO 11135 product and
packaging material must be evaluated for ethylene oxide and humidity
penetration.
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Design complexity
Most subassemblies,
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Parameters to be Verified
Loading in Loading
chamber Pattern
1. Temperature of
Environmental Load
Preconditioning
2. Humidity of
Load
1. Evacuation rate
Initial
Evacuation 2. Number of
nitrogen wash
1. Humidity of load
Humidification
2. Temperature of
load
3. Duration of
Exposure
BI or PCD placement in the product load: - After the product load challenge has
been identified, the BI or PCD positioning and placement can be determined. BIs and
PCDs should be distributed throughout the product load and, as much as possible, in the
same orientation (e.g., vertical).
Following minimum number of BIs/PCDs to be included in each validation cycle (as per
ISO 11135-1: 2007):-
From 10 m3 up to 100 m3, the number of additional BIs is one per additional
cubic meter.
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
minimum number of sensor is two should be placed in sterilization load and it should
include pallet centers, edges and surfaces.
For temperature monitoring in validation one temperature sensor per cubic meter of
product volume with a minimum of 3 sensors should be placed in the load.
Identification of the worst case location or cold spot: - temperature is the easiest
variable to measure and monitor, therefore temperature is used as an indicator of the
worst case location in the sterilization load. During the preconditioning or conditioning
phase temperature profile against time of the sterilization load measured and based on
that data the worst case location or cold spot is identified.
b) Bioburden / BI method
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Place Biological Indicator (BI) with 10⁶ spores of Bacillus atropheus in the PCDs and product
samples in each pallet with humidity and temperature sensor. (Place PCDs to cold spot of the
product load)
If product sterility samples show survival, repeat the run on new load with elevated gas
exposure time until no survival in product and growth in BI (evaluation of BI appropriateness)
Remove the product sample and PCDs and perform sterility test on product sample and BIs
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Sterility test should show no growth for both product and BIs samples
Perform one full cycle (routine process exposure time) on the aerated sterilization load.
3. Biocompatibility test
Establish worst case location in the product load based on temperature distribution and humidity
of load
Place BI with known amount of microorganism in the PCDs, temperature and humidity sensor
Perform 5 fractional cycles with graded exposure time (e.g. 0, 4, 8, 12, 16 minutes)
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
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VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Calculate rate of inactivation (D value) using survival curve or fractional negative method
Place product sample and PCDs in each pallet with temperature and humidity sensor
Aeration
Perform one full cycle (routine process exposure time) on the aerated sterilization load.
Aerate the load and remove the product sample and PCDs
3. Biocompatibility test
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Maintainace of Validation:-
Requalification: -
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Half Cycles:-
No growth
Full Cycles:-
No growth
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Environmental preconditioning: -
Temperature of
preconditioning room
Humidity of the
preconditioning room
Duration of preconditioning
Comments:
Initial evacuation: -
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Comments:
Humidification: -
Level of moisture
Heat
Comments:
Gas concentration
Duration of exposure
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Comments:
Vacuum rate
Comments:
Heated aeration: -
Temperature of room
Aeration duration
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Comments:
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Anticipated load temperature extremes during transport, handling, and storage can be simulated
by following techniques:-
a) Use of cold storage—For example, the product load is stored under refrigeration or
deliberately induced cold temperature. The temperature of the storage area should be
less than or equal to the lowest temperature the product is expected to be exposed to
throughout the year. Product temperature data are recorded during the storage time. The
time in storage should be equal to or greater than the maximum time any product load is
expected to exist under such conditions, or the maximum product temperature while in
storage becomes the minimum acceptable product temperature for a load to be admitted
to the preconditioning phase. This applies to preconditioning or to conditioning when
preconditioning is not used. The use of refrigeration can result in unrealistically low
humidity levels, with the resultant desiccation of the load. A desiccated load can be much
more difficult to sterilize than a non-desiccated load.
b) Temperature modeling—Data analysis of load temperature studies may be augmented
by modeling to establish the additional time required for starting temperatures lower than
those studied. If lower starting temperatures are allowed, the effect of additional
condensation should be evaluated. For example, at the time of validation, the lowest
product load temperature point is 60° F prior to entering preconditioning. Once in
preconditioning, data yield a temperature profile for the worst-case position showing that
the load temperature increases to 100 °F by the end of preconditioning. When the
temperatures over time data are graphed, the linear part of the time/temperature
relationship (which is generally the initial few hours of preconditioning when the
difference between load temperature and preconditioning area temperature is the
greatest) can be used to extrapolate the necessary preconditioning times for sterilization
loads at temperatures lower than 60 °F. Using this technique to calculate a minimum
preconditioning time will yield a time that is greater than that actually required. Other
techniques of temperature modeling can be used.
c) Seasonal validation—preconditioning validation can target those seasons that present
the most extreme temperature and humidity conditions. For example, a validation
conducted during the coldest part of the year (which would also present the lowest
ambient humidity level) could yield minimum preconditioning parameters valid for routine
production cycles during the entire year. However, in cases of validations performed
during the summer, it is advisable to validate the preconditioning process with simulated
cold storage, mathematical modeling or to repeat the preconditioning validation at least
once during the winter to confirm the validity of the parameters.
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Determination of Bioburden:-
Procure ten (10) each product samples randomly from three (3) different batches of routine
production processes.
Send to approved test lab for bioburden evaluation (enumeration of aerobes, fungus, and spores.)
At the test lab, perform the bioburden determinations using a standard method as outlined in IS0 1
1737-1 by extracting each device individually and filtering the extract through a sterile bacterial
retentive filter.
A validation of bioburden recovery should be performed. (An additional five non sterile samples
are required.)
Determine the average bioburden per device for each lot, as well as the overall batch average
bioburden
Calculate the overall average bioburden. If a spike (a single value at least 2 X the overall average)
occurs, the spike value may be used rather than the average for the cycle selection.
Sample item portion (SIP) method for bioburden determination:
Based on following criteria product sample portion determined for bioburden assessment.
1) If the product with an average Bioburden equal to or greater than 1.0 whenever practicable, an
entire product (SIP equal to 1.0) should be used for testing in accordance with ISO 11137:2. When
the use of an entire product is not practicable, a selected portion of product (sample item portion)
may be substituted. The SIP should be as large a portion of item as practicable in order to
manipulate in the laboratory, and should be of a size that can be handled during testing.
2) If a product with an average Bioburden equal to or less than 0.9, an entire product (SIP equal to
1.0) shall be used for testing in accordance with ISO 11137:2.
3) If the Bioburden is evenly distributed on and/or in the item, the SIP may be selected from any
portion of the item. If the Bioburden is not evenly distributed, the SIP shall consist of portions of
product selected at random, which proportionally represent each of the materials from which the
product is made. If the Bioburden distribution is known, the SIP may be selected from the portion
of the product that is considered to be the most severe challenge to the sterilization process.
The value of SIP can be calculated on the basis of length, mass, volume or surface area
Basis for SIP Product
Mass Powders
Gowns
Implants (absorbable)
Volume Fluid
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Appendix 3(GLOSSARY)
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
or international standards.
Chamber
Enclosed area which only accommodates sufficient product to fill the sterilizer. EO chambers are
constructed of steel or stainless steel and are designed to withstand the extreme pressures and
elevated temperatures utilized in the EO sterilization process.
Commissioning
Obtaining and documenting evidence that equipment has been provided and installed in
accordance with its specification and that it functions within predetermined limits when operated
in accordance with operational instructions. All EO sterilization equipment which complies with
ANSI/AAMI/ISO 11135 is commissioned.
Conditioning
Treatment of product within the sterilization cycle, but prior to sterilant admission, to attain a
predetermined temperature and relative humidity. This part of the sterilization process may be
carried out either at atmospheric pressure or under vacuum (see also preconditioning).
Critical Parameters
Parameters identified as being essential to the sterilization process and requiring monitoring.
D-Value
Time (expressed in minutes) required to achieve inactivation of 90 percent of a population of a
test organism under stated exposure conditions. Also referenced as the D10 Value or decimal
reduction value.
Exposure Time
Time for which the sterilizer chamber is maintained within the specified range for temperature,
sterilant concentration, pressure, and relative humidity. Also may be referred to as the time for
which a medical device (load) is exposed at the specified sterilizing conditions.
Failure
Event in which a component does not perform one or more of its required functions within the
specified limits under specified conditions.
Flushing
Procedure by which sterilant is removed from the load and chamber by either multiple alternate
admissions of filtered air or inert gas and evacuations of the chamber or continuous passage of
filtered air or inert gas through the load and chamber.
Inactivation
Loss of the ability of microorganisms to grow and/or multiply under specified culture conditions.
Indicator
Combination of the indicator agent and its substrate in the form in which it is intended to be
used.
Inoculated Carrier
Carrier on which a defined number of test organisms have been deposited.
Installation Qualification
Obtaining and documenting evidence that equipment has been provided and installed in
accordance with its specifications and that it functions within predetermined limits when
operated in accordance with the operational instructions.
Manufacturer
Natural or legal person packaging or sterilizing a medical device.
Medical Device
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Any instrument, apparatus, appliance, material, or other article, whether used alone or in
combination, including the software necessary for its proper application intended by the
manufacturer to be used for human beings for the purpose of:
diagnosis, prevention, monitoring, treatment, or alleviation of disease;
diagnosis, monitoring, treatment, alleviation of, or compensation for an injury or handicap;
investigation, replacement, or modification of the anatomy or of a physiological process;
control of conception; and which does not achieve its principal intended action in or on the
human body by pharmacological, immunological, or metabolic means, but which may be
assisted in its function by such means.
Microbial Barrier
Ability of the packaging system to prevent the ingress of microorganisms under specified
conditions.
Microbiological Challenge
Biological indicators, biological-indicator test packs, or inoculated product that contain known
populations of microorganisms and can be used in testing sterilization cycles.
Overkill Sterilization Process
Process which is sufficient to provide at least a 12-logarithmic reduction or 12 D inactivation of
an appropriately resistant biological indicator with an established D value.
Package Integrity
Unimpaired physical condition of a final package.
Parametric Release
Declaring product as sterile based on physical and/or chemical process data rather than on the
basis of sample testing or biological indicator results.
Performance Qualification
Obtaining and documenting evidence that the equipment, as commissioned, will produce
acceptable product when operated according to the processing specifications.
Positive Sterility Test
Sterility test samples which exhibit detectable microbial growth after incubation.
Preconditioning
Treatment of product prior to the sterilization cycle in a room or chamber to attain specified limits
for temperature and relative humidity.
Preconditioning Area
Either a chamber or a room in which preconditioning occurs.
Process Lethality
Capability of the sterilization process to destroy microorganisms.
Process Qualification
Obtaining and documenting evidence that the sterilization process will produce acceptable
health care products.
Product
Generic term used to describe raw materials, intermediate products, subassemblies, and
finished medical devices.
Product Qualification
Obtaining and documenting evidence that the health care product will be acceptable for its
intended use after exposure to the sterilization process.
Qualification
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TITLE:- VALIDATION PROTOCOL FOR ETHYLENE OXIDE
STERILISATION PROCESS
VALIDATION PROTOCOL NO: EFFECTIVE DATE:-
Documented evidence that all prescribed design and performance requirements are met.
Requalification
Repetition of part of all of the validation test requirements for the purpose of reconfirming
process reliability.
Sterilant
Microbicidal agent in the physical form in which it is active.
Sterile
Free from viable microorganisms. In practice, no such absolute statement regarding the
absence of microorganisms can be proven (see sterilization).
Sterility
State of being free from viable microorganisms. In practice, no such absolute statement
regarding the absence of microorganisms can be proven (see sterilization).
Sterility Assurance Level (SAL)
Probability of a viable microorganism being present on a product unit after sterilization. SAL is
normally expressed at 10-n.
Sterility Test
Test performed to determine if viable microorganisms are present.
Sterilization
Validated process used to render a product free from viable microorganisms. In a sterilization
process, the nature of microbial death is described by an exponential function. Therefore, the
presence of viable microorganisms on any individual item can be expressed in terms of
probability. While this probability may be reduced to a very low number, it can never be reduced
to zero. The probability can be expressed as a sterility assurance level (SAL).
Sterilization Cycle
Defined sequence of operational steps designed to achieve sterilization that is carried out in a
sealed chamber. Specifically for EO sterilization, the treatment in a sealed chamber comprising
air removal, conditioning, injection of sterilant, exposure to ethylene oxide, and removal of
ethylene oxide.
Sterilization Load
Goods that are to be or have been sterilized simultaneously in the same sterilization chamber.
Sterilization Process
All treatments which are required to accomplish sterilization, including preconditioning, the
sterilization cycle, and aeration.
Validation
A documented procedure for obtaining, recording, and interpreting the results needed to show
that a process will consistently yield a product complying with predetermined specifications.
Validation is considered as a total process that includes written protocol, evidence that the
equipment as installed meets design criteria and specifications (equipment qualification), use of
calibrated instruments to collect data, and evidence that the equipment can deliver the process
within specified tolerances under established operating conditions and is reproducible as
demonstrated by replicate runs and process challenges (performance qualification).
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