10 Common Mistakes in Sterilization of Surgical Instruments and How to Avoid Them

It is no longer a hidden fact that we often hear about some potential diseases originating in patients right after being treated by contaminated or improperly sterilized instruments used during surgery.  

So, effective sterilization of surgical instruments is crucial to avoid germs transmittance to patients and doctors. This protects patients and the medical professionals handling the equipment. 

Despite all the potential concerns of improper cleaning and sterilizing instruments, some healthcare facilities still unknowingly make mistakes in the sterilization process, which can lead to infections and compromised patient care. 

This article will discuss 10 common mistakes in sterilizing surgical instruments, highlight how they occur, and offer practical solutions.

Importance of Cleaning and Sterilization of Surgical Instruments

Sterilizing instruments and medical equipment are important so hospitals, practices, and other healthcare facilities can safely care for their patients. These institutions' staff routinely use instruments on many patients, so there is a greater chance that bacteria and other harmful things come into contact with them. 

It is also important because proper sterilization of surgical instruments ensures that doctors and nurses don’t let patients get infected while treating them. 

Moreover, as a surgeon treating so many cases of HIV patients, if you feel that you have any symptoms resembling HIV disease, go priorly for the anti-HIV test. This means that medical staff can also be infected if no precautionary measures are adopted.

So, to avoid all the chances of getting infected or infecting patients with contaminated instruments, always clean and sterilize the surgical instruments properly so that the invisible hazardous germs are totally removed before using them in the procedure/surgery.

10 Common Mistakes in Surgical Instruments Sterilization & Its Solutions 

1. Inadequate Pre-Cleaning

Skipping or performing insufficient pre-cleaning leaves organic debris on instruments. This debris can block sterilizing agents and lead to incomplete sterilization. Proper cleaning of surgical instruments ensures better sterilization. 

Problem:

• Residue blocks sterilization.
• Increases infection risk.
• Sterility is compromised.
• Contaminants can damage sterilizers.

Solution:

• Use enzymatic cleaners.
• Rinse instruments thoroughly.
• Establish strict pre-cleaning protocols.
• Inspect for debris before sterilizing.

2. Using Incorrect Sterilization Methods

Different instruments require specific methods for sterilization of surgical instruments. Using the wrong method can damage instruments or leave them inadequately sterilized.

Problem:

• Improper method damages tools.
• Ineffective sterilization occurs.
• Shortens instrument lifespan.
• May void manufacturer warranties.

Solution:

• Follow manufacturer guidelines.
• Match sterilization to material.
• Train staff on proper methods.
• Stay updated on sterilization procedures.

3. Overloading the Sterilizer

Overloading the sterilizer prevents proper heat or air circulation. This can result in uneven sterilization and contamination risks.

Problem:

• Blocks heat and airflow.
• Sterilization procedure is incomplete.
• Contamination risk increases.
• Instruments may sustain damage.

Solution:

• Load sterilizer as per capacity.
• Avoid stacking instruments.
• Space items evenly for airflow.
• Regularly inspect sterilizer capacity.

4. Incorrect Temperature and Pressure Settings

Each sterilization method requires specific temperature and pressure settings. 

Incorrect settings can render the process ineffective.

Problem:

• Bacteria may survive.
• Inconsistent sterilization occurs.
• Safety is compromised.
• Instruments may deform under incorrect settings.

Solution:

• Verify settings before use.
• Follow standard temperature guidelines.
• Train staff to handle sterilizers correctly.
• Calibrate sterilizers periodically.

5. Ignoring Instrument Drying

Leaving instruments wet after the sterilization procedure fosters bacteria growth and risks recontamination. Moisture can also damage tools over time.

Problem:

• Moisture fosters bacteria.
• Risk of tool corrosion.
• Reduces storage sterility.
• Wet tools attract dust particles.

Solution:

• Dry tools thoroughly post-sterilization.
• Store only when completely dry.
• Use drying mechanisms when needed.
• Monitor the humidity in storage areas.

6. Improper Instrument Handling

Sterilized instruments must always be handled in a sterile environment. Using bare hands or placing tools on non-sterile surfaces compromises their sterility and increases the risk of contamination.

Problem:

• Bare hands reintroduce bacteria.
• Non-sterile surfaces contaminate tools.
• Sterilization efforts are wasted.
• Reduces patient safety.

Solution:

• Handle tools with sterile gloves.
• Maintain a sterile environment.
• Train staff on proper handling techniques.
• Use sterilized trays for transport.

7. Using Expired Sterilizing Agents

Expired sterilizing solutions lose their potency, leading to incomplete sterilization of surgical instruments. Relying on outdated agents poses serious risks to patient safety.

Problem:

• Agents lose effectiveness.
• Bacteria may survive the process.
• Patient safety is compromised.
• Sterilization time increases unnecessarily.

Solution:

• Regularly check expiration dates.
• Replace outdated sterilizing agents.
• Conduct inventory checks routinely.
• Use digital tracking for supply management.

8. Skipping Biological Indicators and Testing

Biological indicators verify the effectiveness of sterilization cycles. Without regular testing, you cannot ensure that instruments are properly sterilized.

Problem:

• Sterility is unverified.
• Contamination risks increase.
• Safety standards may not be met. 
• Increases liability for healthcare facilities.

Solution:

• Use spore tests weekly.
• Monitor sterilizer performance.
• Maintain records of test results.
• Schedule routine audits for testing.

9. Improper Storage of Sterilized Instruments

Storing sterilized instruments in non-sterile or poorly maintained environments exposes them to contamination. Dust, moisture, and improper handling negate the sterilization process.

Problem:

• Tools are exposed to contaminants.
• Dust and moisture can recontaminate.
• Sterility duration is reduced.
• Risk of accidental damage increases.

Solution:

• Use sterile, sealed storage.
• Keep instruments in clean environments.
• Inspect storage areas regularly.
• Label storage areas clearly for sterility levels.

10. Failure to Train and Educate Staff

Untrained staff may overlook critical sterilization steps or mishandle equipment, leading to errors. Regular training is essential for maintaining safety standards.

Problem:

• Staff lack knowledge of best practices.
• Errors in the sterilization of surgical instruments process occur.
• Patient infection risks increase.
• Productivity may suffer due to mistakes.

Solution:

• Conduct regular training sessions.
• Update staff on new sterilization methods.
• Provide practical, hands-on workshops.
• Encourage feedback for process improvements.

Which Chemicals Can Corrode and Destroy Surgical Instruments?

Stainless steel's durability and corrosion resistance depend on its inherent passive layer, which is most often a chromium or iron oxide layer. It is highly resistant to corrosion, salt solutions, and other harsh chemicals. However, it is still delicate to salt solutions, chlorides, and other harsh chemicals.  

Technicians must also remember that rinsing with distilled water ensures proper cleaning, as the high concentration of minerals in tap water can cause spotting or staining on instruments.

Specific types of chemicals that can potentially damage surgical instruments include:

• Hydrogen peroxide
• Alkaline-based cleaning solutions
• Dish soap or laundry soap
• Ammonia
• Bleach
• Iodine products
• Hydrochloric acid

Essential Tips for Effective Sterilization of Surgical Instruments

Before final sterilization, instruments should always be treated as though they are contaminated.

Below are the essential tips for the sterilization of surgical instruments:

• Pre-clean thoroughly to remove visible debris.
• Choose the right sterilization methods for surgical instruments based on the material used in manufacturing.
• Follow manufacturer guidelines for each tool.
• Avoid overloading sterilizers to ensure even distribution.
• Use sterilization indicators to verify effectiveness.
• Store sterilized tools properly in sealed packaging.
• Regularly test sterilizers with biological indicators.
• Dry instruments after sterilization to prevent contamination.
• Separate clean dirty areas to avoid cross-contamination.
• Monitor sterilization times and temperatures closely.
• Train staff on instrument cleaning protocols to ensure safe sterilization.

GerMedUSA: Your Trusted Partner for Surgical Instruments

GerMedUSA manufactures high-quality surgical instruments and knows the importance of having the right medical instruments at your fingertips. We offer thousands of quality medical instruments needed at any specialty practice. Our surgical instruments are made of German stainless steel, which ensures they can withstand repeated use. 

We have over 30 years in the market to serve medical professionals with quality instruments.

Additionally, we offer a customization option. If you need custom instruments, packs, or sets, we can help. Share your requirements with us, and we can manufacture it for you. 

With the right equipment and sterilization processes, you can avoid these common mistakes and ensure a clean, sterile environment for every procedure.

FAQs

What are the most reliable sterilization methods for surgical instruments?

Autoclaving and dry heat are among the most reliable sterilization methods. Chemical sterilization is also effective for specific instrument types. The choice depends on the material and sensitivity of the instruments.

Can ultrasonic cleaning replace sterilization?

No, ultrasonic cleaning only removes debris and contaminants. It’s an essential pre-cleaning step, 

However, sterilization of surgical instruments should always be followed to kill microorganisms.