Hard Facts About Rigid Sterilization Containers

Instrument Reprocessing and Care

By: Sheryl Eder

Published: 1/15/2019

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Consider these factors to maintain the integrity of your instruments.


SEALED-IN STERILITY Many are turning to rigid containers to avoid the punctures and tears in packaging that commonly occur during storage and transport of wrapped sterile instrument sets.

The No. 1 benefit of rigid containers? That’s easy. They eliminate the punctures and tears of “torn-wrapper” syndrome, which gives you added assurance that your instruments are sterile and protected. Running a close second? Containers reduce mounds of discarded blue wrap. Here are 5 more advantages worth considering.

1 They’re stackable. Rigid containers aren’t susceptible to compression, so you can stack them and conserve precious shelf space in storage. But what happens when you stack wrapped trays? The ones underneath can develop air pockets and holes from the weight and pressure. A note about stacking containers: You’re not playing Jenga. Stack 2 or 3 high. Not only will this increase stability to prevent containers from falling over, but it will also facilitate first-in, first-out rotation.

2 They’re less time-consuming. Packaging in containers can be quicker than wrapping. No matter how efficient your processing technicians are, wrapping and taping instruments adds time to the process — especially larger containers.

HARD CASES Compression can compromise sterility, but that's not a problem when you stack rigid containers on your storge shelves.   |  Gregory P. DeConciliis, PA-C, Boston Out-Patient Surgical Suites

3 They’re easy to transport. Dragging heavier trays across a wire shelf in storage or when removing from a case cart can cause abrasions or tears in the wrap. A small defect in a wrapper can impair sterility and delay a case until your sterile processing staff can retrieve a replacement set for the case. Rigid containers are easier to carry, meaning there’s a smaller chance of transport damage.

4 They’re eco-friendly. Blue sterilization wrap is made of double-ply polypropylene, which takes up to 30 years to biodegrade. Yes, you can recycle and repurpose blue wrap (see “Blue Wrap Bed Rolls for the Homeless”), but much of it ends up in landfills.

5 They’re budget-friendly. Although the one-time cost outlay can be expensive, with proper maintenance, containers can last for as long as 10 years. By weighing the cost of cancelled and delayed surgeries due to sterile packaging issues, rigid containers may represent a significant cost savings in re-work, rescheduling and lost OR time. For loaners, rigid containers provide an added benefit. Loaners usually don’t have a back-up. If there’s a hole in the wrapper, you might have to reschedule the case. Not a problem with rigid pans.

Proceed with caution

This is not to say rigid containers are problem-free. For example, the weight they add to the tray could be troublesome. AAMI standards recommend tray weight of no more than 25 pounds and adding a rigid pan can put your trays over the mark. So while it certainly make sense to use containers for orthopedic and neuro surgery instruments due to the weight of those sets and the potential for tears and abrasions in the wrap, keep the weight restrictions in mind.

There’s also size to consider. Containers are bigger, and you might not be able to fit as many trays into the sterilizer, so your loads may be smaller and more frequent. And you might need multiple sizes of rigid containers, with varying depths and lengths, to accommodate all sizes of instruments.

Then there’s maintenance. Loose locks, falling retention plates and worn gaskets will not maintain sterility. Inspect your containers every time you use them. Ensure the lids fit correctly and that there are no cracks or breaks. Your OR staff should ensure that tamper locks are in place and filters are intact before using the contents in a sterile procedure.

Don’t forget the added workload with metal trays. They must be disassembled, washed and disinfected before every use, which adds to the reprocessing workload.

If your facility uses hydrogen peroxide (gas or plasma) sterilization, you’ll need 2 different types of containers: one that can go in steam sterilization and one that can go in hydrogen peroxide sterilization. Not all instrument systems are validated for all rigid containers. Whether the items are loaned or owned, current guidelines require scientific validation to ensure the weight, density and tray configuration are appropriate for sterilization within the sterilization container. Orthopedic sets with multiple heavy instruments and multi-levels of implants are of concern due to their complexity.

Do your research

Brush up on studies that compare using sterilization wrap to rigid containment systems. Decide what you hope container systems will solve for you (tears in wrappers, space savings, decreased waste disposal) and compare it to the cost of purchase, maintenance and increased workload for decontamination staff. OSM

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