The issue of steam sterilizer wet loads isn’t new, but it has been getting a lot of attention lately. A number of pertinent articles have reached the autoclave community so far this year. Sterilizer manufacturer ETC issued helpful technical information this month. Healthcare Purchasing News also featured a piece on wet packs complete with advice from many industry professionals on solving this persistent problem.

Excessive moisture can easily build up on wrapped instrument trays during or immediately following an autoclave cycle. When this occurs, the entire load has to be considered contaminated. Reprocessing these materials places a strain on SPD technicians and equipment alike. The delays also pose a serious time management problem for sensitive applications. Unfortunately, flash sterilization is one of the processes most prone to condensation build up. This means instruments that should be rushed to the OR for immediate use must instead be re-sterilized.

Prime Culprits For Wet Load Problems

The causes for wet packs fall into two basic categories: equipment and operation. Generally, the autoclave itself is not the problem. However, the steam supply used often is. If the steam contains too much water vapor, adjusting settings and cycle times may not eliminate the problem. A qualified service technician can perform testing to verify whether or not the steam supply line is the reason of your wet loads. Fixing this flaw at its source may require repair or redesign of your boiler system. Or, you may need to overhaul the insulation on the piping leading to the sterilizer. Making any necessary upgrades is a wise investment.

Other equipment considerations include ensuring proper functioning of steam traps and drains. Introducing steam at controlled intervals can help also prevent the buildup of condensate. Some software and valve configurations allow for this type of adjustment. Adequate heating at the beginning of each cycle is important too. It is possible to add a heat exchanger to the in-bleed air assembly on some models to aid this quick initial heating process.

Once any problems with the equipment have been ruled out, the only other factor is the person operating the autoclave. Adequate training and staffing can reduce many of the common errors technicians make when running cycles. Here are some ways SPD personnel can help ensure dry loads every time:

- All instruments should be dried prior to processing

- Loads should be kept to a reasonable size and weight

- Sets should be wrapped or containerized using approved materials and techniques

- Loads should be distributed correctly within the chamber

- Cycle times should be of adequate length and temperature

- Cool down and drying time should not be shortened

Ensuring the sterility of each load and reducing the number of times instruments must be reprocessed should be the goal of every facility that uses a sterilizer. If you have found no problems with your steam supply or operational techniques and you are still experiencing wet loads, there could be a problem with your autoclave. A service technician may be able to fix the issue. However, you may need to upgrade to a larger model if you are handling a high volume of instruments. For information on finding an affordable replacement, please take advantage of our free report.