Evaluation of Novel Process Indicators for Rapid Monitoring of Hydrogen Peroxide Decontamination Processes

Comparison of one-step with two-step production of Bacillus atrophaeus spores for use as bioindicators

The production method of spores significantly influences the resistance of spores used as bioindicators (BI) in the validation of sterilization of packaging material surfaces in aseptic food manufacturing. Therefore, the standardization of the spore production method represents an important and desirable goal in industrial BI production to ensure reliable validation test results. Previously, we recommended a two-step production approach for submerged spore production, in which the cultivation phase to obtain high cell mass was separate from the sporulation phase. In this work, a one-step manufacturing process was investigated to reduce production complexity and facilitate standardization of spore production. It was found that one-step BI production is technically possible but at the expense of spore yield. The two-step manufacturing process can realize almost 10-fold higher spore yields.

Submerged Bioreactor Production of Geobacillus stearothermophilus ATCC 7953 Spores for Use as Bioindicators to Validate Hydrogen Peroxide Inactivation Processes

In the food and pharmaceutical industries, evaluating the sterilization performance preceding aseptic production processes is of central importance. In the case of hydrogen peroxide sterilization of solid surfaces, bioindicators (BI) consisting of spores of Bacillus atrophaeus or Geobacillus stearothermophilus are used to validate the effectiveness and efficiency of the inactivation procedure. Commercial production of G. stearothermophilus is commonly performed on agar plates, where cultivation and sporulation conditions are not well-defined. Therefore, the produced BI can vary in their resistance, which in turn creates unacceptable uncertainties in the evaluation of aseptic processes. Submerged production in the bioreactor would allow more control over sporulation conditions, while reducing production time, resistance variability, and avoidance of false-positive or false-negative test results. In addition, submerged production of G. stearothermophilus so far was a challenge to achieve sufficiently high spore concentrations for BI production. This study reports on the development of a method for submerged production of G. stearothermophilus spores (pH 7.0, 57 °C, 30% pO₂) that can achieve 1.6 × 10⁷ spores/mL with a resistance against 35% H₂O₂ at 25 °C of D_{25°C,35% H2O2} = 73 s. This resistance ranks within the range of commercially available BI, making the results directly transferable to industrial applications.

Determining the Effectiveness of Decontamination with Ionized Hydrogen Peroxide

Introduction

Ionized Hydrogen Peroxide (iHP) is a new technology used for the decontamination of surfaces or laboratory areas. It utilizes a low concentration of hydrogen peroxide (H2O2) mixed with air and ionized through a cold plasma arc. This technology generates reactive oxygen species (ROS) as a means of decontamination.

Objectives

The purpose of this study is to evaluate the diffusion effect of iHP and its decontamination capabilities using biological and enzyme indicators.

Methods

A gas-tight fumigation room with a volume of 880 ft3 was used for the decontamination trials. During the decontamination process, empty animal cages were placed inside to create fumigant distribution restrictions. Spore and enzyme indicators were placed in eleven locations throughout the decontamination room. Generation of iHP was done with the use of TOMI's SteraMist Environmental System and the SteraMist Solution, with 7.8% H2O2 at a dose of 0.5 ml per ft3.

Results

For the decontamination of 1hr, 2hrs, 6hrs, and 12hrs, the biological indicators of B. atrophaeus in Stainless Steel (SS) Disk in Tyvek envelope have an inactivation rate of 94%, 97%, 100%, and 100%, respectively. For G. stearothermophilus in SS disk and Tyvek envelope, it has 82%, 68%, 100%, and 100%, respectively and, for G. stearothermophilus in SS strips it has an effective rate of 88%, 67%, 91%, and 100%, respectively.

Conclusion

iHP inactivates spores, and the residual tAK activity indicates a gas-like fumigant diffusion due to the uniformity of the inactivation without the use of oscillating fans as the contact time is extended.

Terminal sterilization of medical devices using vaporized hydrogen peroxide: a review of current methods and emerging opportunities

Medical devices are an important and growing aspect of healthcare provision and are increasing in complexity to meet established and emerging patient needs. Terminal sterilization plays a vital role in the provision of safe medical devices. While terminal sterilization technologies for medical devices include multiple radiation options, ethylene oxide remains the predominant nonthermal gaseous option, sterilizing c. 50% of all manufactured devices. Vaporized hydrogen peroxide (abbreviated VH2O2 by the International Organization for Standardization) is currently deployed for clinical sterilization applications, where its performance characteristics appear aligned to requirements, constituting a viable alternative low-temperature process for terminal processing of medical devices. However, VH2O2 has operational limitations that create technical challenges for industrial-scale adoption. This timely review provides a succinct overview of VH2O2 in gaseous sterilization and addresses its applicability for terminal sterilization of medical devices. It also describes underappreciated factors such as the occurrence of nonlinear microbial inactivation kinetic plots that may dictate a need to develop a new standard approach to validate VH2O2 for terminal sterilization of medical devices.