sterilisation of your medical device - nelson labs...common methods for industrial sterilization of...
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Sterilisation of your Medical device
05 MARCH 2020
ANNICK GILLET
TECHNICAL DIRECTOR, EO PHARMA
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CONFIDENTIAL 1
What’s the difference between
these two devices ?
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• Free from viable microorganisms.
• Sterility is a probability as cannot be proven.
• Products can only be labelled ‘STERILE’ if the chance of an item remaining contaminated after sterilization is less than to one chance in a million (SAL 1x10-6 or less).
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How can we obtain a sterile product ?
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• Different possibilities
• The method depends about the nature of the product (material, temperature sensitivity …Etc.) and intended use (e.g. external, injectable, ophthalmic …Etc.)
• Heat sterilization is the most popular method.
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CONFIDENTIAL
Sterilization methods
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Sterilization by Radiation and by Ethylene Oxide gas are the most common methods for industrial sterilization of Medical Devices
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The application of a lethal sterilizing agent to finished product within a sealed container to achieve a predetermined sterility assurance level (SAL) of 10⁻⁶ or better – GMP Annex 1 Draft
Decontamination Vs Sterilization
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Decontamination Cleaning Disinfection Sterilization
A process that eliminates viable bioburden via use of chemical agents GMP Annex 1 Draft
Removal of contamination from an item to the extent necessary for further processing or for intended use ISO 11139:2006
Decontamination Cleaning Disinfection
The process by which surface bioburden is reduced to a safe level GMP Annex 1 Draft
Sterilization
Sterilization – Basics
Validation
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CONFIDENTIAL 6
Sterilization – Basics
Initial contamination level • Microbiological status
raw material and components
• Cleaning and disinfection procedures
• Environment control
• Personnel Hygiene
Sterility is much more than just a process!
Product preservation
• Packaging
• Storage
Equipment
• Control
• Maintenance
• Calibration
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Method (Technology)
Product Constraints
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Design cycle parameters
STERILE Product
Selection of the Sterilization Method
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Drug development
Product quality
Selection of the Sterilization Method
R&D, Materials
& Packaging Optimization
Regulatory Manufacturing & Clinical Trials
Manufacturing
Sterilization Quality
Control Tests Distribution
Think about sterilisation process selection up front / early during product development
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• Linear relationship bioburden/ treatment applied (dose or exposure time)
• Any terminal sterilization process is validated based on that assumption
• You can predict the required time/dose to achieve a defined SAL
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Initial contamination
Sterile (SAL ≤10-6)
Sterilization process
Terminal Sterilisation
Sterilization – Basics
Challenge
Bioburden
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Microbial
Challenge
Product Bioburden
Sterilization – Basics
• Bioburden test • Product Sterility test
• Challenge (BI) Sterility test
Laboratory Tests:
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Two methods to generate irradiation :
1 2
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Sterilization by Irradiation
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Sterilization by Irradiation : Gamma
1
10
50
100
500
1000
Typical chest X-Ray (0,1 mGy)
Dose that may cause symptoms of radiation sickness (1000 mGy)
Sterilization Dose 10.000 – 40.000 Gy
Effects of ionizing Radiation on DNA
Scale of irradiation :
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Source: 60Co (mostly)
Isotropic radiation flux
Sterilization by Irradiation: Gamma
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Layout E-Beam facility
Sterilization by Irradiation : E-beam
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Electron Beam & Gamma, Penetration
Sterilization by Irradiation
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Method VDmax
Microbial
Challenge
Product Bioburden
Standard Distribution of resistances (SDR)
Sterilization by Irradiation
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Dose Mapping
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Establish the distribution of absorbed dose within the irradiation container when packed with product in a defined configuration
• Min and Max limits of absorbed Dose • Define cycle time • Establish monitoring points
Min Dose
Max Dose
Sterilization by Irradiation
Fig.1 Dosimeter
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Quarterly Dose Audit (QDA)
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Sterilization by Irradiation
Check bioburden Can vary due to
• Season
• Environment …
Verification Dose (Often In a research irradiator)
Ex: 8,7KGy
Sterility Test
SAL10-1
Every 3 months
Confirm Product SAL 10-6
With Routine Dose Ex:25KGy
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CONFIDENTIAL
The Ethylene Oxide Sterilization Process
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Ethylene Oxide is an extremely reactive gas creating irreversible reaction with cells DNA and proteins. Due to its toxicity and difficulty, this makes this method the last choice. Anyway in regards of modern product complexity, it’s still one of the most commonly used industrial method for medical devices sterilization.
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Sterilization by Ethylene Oxide
• Product sterilized on pallet • Different capacity ( 1 to 32 PL) • Gouped by family/category
Fig.1 Eto Sterilization Chamber
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Device/packaging must be permeable to the gas • No aqueous substances
• No protein-type materials
• Powders, batteries, electronic circuits have to be assessed (risk of explosion)
• Vacuum/heat can have adverse impact on some packaging (bubble wrap packaging, polystyrene)
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Sterilization by Ethylene Oxide
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CONFIDENTIAL 22
There are 4 key parameters to monitor the process:
Deactivation of Microorganisms
A standard cycle is typically running at 50°C, with an exposure time of 3 hours at a concentration of 600mg/L with a humidity around 50%.
The cycle parameters are optimized for each type of product to sterilize.
Sterilization by Ethylene Oxide
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CONFIDENTIAL 23
The sterilization process has 3 key phases: The main challenge is getting the product sterile, effective with an acceptable level of EO gas residues
In total the sterilization process takes approximatively 4 days in parallel with 7days incubation for the BI:
12h Preconditioning
8h
Chamber cycle
3 days Aeration
7 days BI Incubation
Sterilization by Ethylene Oxide
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We design the validation to show that the BI in the external challenge is more difficult to kill than natural occurring bioburden
Monitoring EO Sterilization – Biological Indicators
External
Challenge
Internal Challenge
Product Bioburden
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Sterilization by Ethylene Oxide
Fig.1 Biological indicator
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• Ethylene Oxide (EO)
• Ethylene Chlorohydrin (ECH) = EO + HCL
• Ethylene Glycol (EG) = EO + H2O
Compounds that remain on product after EO sterilization:
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Sterilization by Ethylene Oxide
Prolonged Exposure
Permanent Contact
Limited Exposure
(<24h)
There are Three Patient Exposure Categories:
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Drug products
API Prefilled syringes
(external) Active Implants Auto-Injector
(external)
Surgery packs Catheters vials Bandages
Medical Devices
Sterilization by Ethylene Oxide : Product examples
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Sterilization : Comparison Radiation & Ethylene Oxide
Parameter Gamma E-Beam EO
Process Individual product, box, tote, pallet
Boxes Pallets
Material compatibility Not compatible with some type of polymers (PTFE and PVC affected)
Wider polymer compatibility compared to Gamma
Very good No liquid/proteins Low Temperature (40-55°C)
Validation Straightforward Straightforward Complicate
Validation principle Based on bioburden Based on bioburden
Based on Bio Indicators
Requalification Every 3 months (QDA) Every 3 months (QDA)
Every 2 years (1 cycle)
SAL <10exp6 <10exp6 <10exp6
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Sterilization : Comparison Radiation & Ethylene Oxide
Parameter Gamma E-Beam EO
Tolerance for density variation
High Low Medium
Routine monitoring • Only a few parameters (Time, Size, density)
• Dosimeter
• Higher Nb of parameters
• Dosimeter
• Multiple cycle parameters
• BI (unless parametric release)
Residues None None ETO,ECH,(EG)
Volumes High Limited High
Turn time Fast (<24 hours) Very Fast (<8 hours)
Long (1 week)
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• Surface sterilization (Drug-delivery devices, Orthopaedic implants, implantable sensors )
• Short process time (2-4hours).
• Safe and simple to use: non-flammable, non-explosive and non-carcinogenic
• Wide variety of compatible materials (if not cellulose based)
• Allows processing of moisture/temperature sensitive materials
• Low residuals
• Small volume – Scale up ?
An alternate possibility ?
Sterilization by Nitrogen Dioxide
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CONFIDENTIAL 30
Different ways to get there !
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CONFIDENTIAL 31
The invisible crucial process!
Sterilization: