Toward Enhanced Machine-Based Release in X-ray Sterilization.

Trends toward the use of irradiator parameter release (also called machine-based release) put pressure on equipment manufacturers to guarantee accuracy and reliability of monitored process parameters. In the specific case of X-ray processing, relevance of these monitored parameters is questionable due to the additional difficulty coming from the fact that the X-ray converter does not have associated parameters or a monitored feedback mechanism. To bridge this gap, this article presents a novel method to verify in real-time consistency of certain X-ray field properties. It covers the description of an X-ray flux monitor and its experimental characterization. The proposed detector can be used as a control and monitoring tool in addition to the conventional "passive" dosimetry per ISO 11137-1 and ISO 11137-3. It can detect photon flux deviation on the order of magnitude of 1%. Its performance would allow real-time monitoring of each pallet being processed and ensure that the correct X-ray beam is directed to the product. Further, the known response of the detector to a product can serve as a validation that the correct product is in front of the beam. Moreover, a detector of this type could contribute to moving from the current dosimetric release to irradiator parameter release. Compared with current practices, benefits would include an increased number of control points used to verify process conformity, real-time information on the radiation field (process output validation), limited manual handling of dosimeters, and verification that the product treated is the same as the performance qualification dose-mapped product.

Radiation Process Control: Product Dose vs. Process Dose.

The requirements for the irradiation of healthcare products have been well established and implemented across the globe for several decades. The ISO 11137 series of standards gives the user the road map for designing a radiation process that will routinely deliver the required sterility assurance level so that product consistently meets specifications. The latest addition to the ISO 11137 series of standards should provide much-needed guidance around establishing a highly reproducible process based on a statistical analysis of the validated state of control. Most industries refer to this as "process control."

Programmatic Assessment of Potential Induced Radioactivity in Electron Beam Sterilization of Healthcare Products.

ISO 11137-1:2006 Sterilization of Healthcare Products-Radiation requires that the potential for induced radioactivity be evaluated for medical devices irradiated with electrons with energy more than 10 MeV. For a manufacturing operation where new devices are being developed, a practical program for making such an evaluation should be engrained in the process, including the device design phase, where selection of materials can make a difference in the potential for activation to occur as a result of the irradiation process. The program, which is based on general assumptions as to the likely activation processes and generalized process assessments is being implemented in three phases: (1) incorporating materials consideration in the design phase, (2) evaluating potential activation empirically, including measurement at the point of irradiation, and (3) implementing routine procedures for the program, including developing a data base of results for consideration in future design efforts.