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Medical Device Sterilization Validation

Life Science Outsourcing has in-depth expertise selecting and executing medical device sterilization validation services in strict compliance with regulations and ISO standards.

LSO employee operating EtO sterilization machine

Sterilization Validation
for Compliance and Market Readiness

Ensure your medical devices meet the highest regulatory standards with proven sterilization validation. Our expert team streamlines compliance, minimizes risk, and accelerates time-to-market. Discover how we support your validation needs.

What is medical device sterilization validation?

The objective of validation is to determine that the sterilization process will consistently achieve sterility and that it won’t have an undesirable effect on the device or its packaging.

Who needs sterilization validation?

All medical device and pharmaceutical manufacturers in the United States are required to validate sterility assurance processes for products marketed as sterile. For reprocessed medical devices, the manufacturer is to validate instructions that render the product fit for use.

How does medical device sterilization validation work?

Validation elements

Common elements in the validation of any sterilization process include:

  • Parameter selection / Sterilization cycle development
  • Installation and operational qualification
  • Performance qualification
  • Routine monitoring
  • Process maintenance and periodic review
  • Change control

Validation protocols

The FDA definition for Validation Protocol:

“A written plan stating how validation will be conducted, including test parameters, product characteristics, production equipment, and decision points on what constitutes acceptable test results.”

It is important that the manufacturer prepare a written validation protocol which specifies the procedures and tests to be conducted and the data to be collected. The purpose of the collected data must be clear, it must reflect facts, and it must be accurate. The protocol should specify a sufficient number of replicated process runs to demonstrate consistency in results and measure any process variations between runs. Validation documentation should include evidence of the suitability of materials and the performance and reliability of equipment and systems.

A Validation Protocol typically consists of:

  • Purpose and objectives
  • Equipment
  • Tests to be performed and rationale
  • Detailed test methods
  • Acceptance criteria
  • Approvals
  • Effective date
  • Supporting documentation

Validation processes for sterilization methods

  1. Ethylene Oxide (EtO) Validation
    • IQ/OQ of equipment
    • Product bioburden test
    • Fractional cycle with biological indicators and product sterility samples
    • Half & full cycles with biological indicators, temperature sensors, and humidity sensors
    • EO residuals tests
  2. Radiation Validation
    • IQ/OQ of equipment
    • Dose mapping study using dosimeters at various locations
    • Determination of product bioburden
    • Verification dose determination based on product bioburden.
    • Irradiate products at “sublethal” verification dose level.
    • Test the verification dosed samples for sterility.
  1. Steam Validation
    • IQ/OQ of equipment
    • Half & full cycles with biological indicators and temperature sensors
Close-up of a gloved hand placing a EtO sterilization canister into a 3M Steri-Vac GS8X system.

What standards apply?

According to the FDA Process, validation is a requirement of the Current Good Manufacturing Practices Regulations for Finished Pharmaceuticals, 21 CFR Parts 210 and 211, and of the Good Manufacturing Practice Regulations for Medical Devices, 21 CFR Part 820, and therefore, is applicable to the manufacture of pharmaceuticals and medical devices. Sterilization processes are validated to their respective standards (e.g., ISO 11135, ISO 11137, and ISO 17665).

Why LSO?

LSO will guide you through the sterilization and validation of single use and reusable products and related documentation based on our extensive experience, knowledge, and industry-leading expertise.

Full EtO Validation

Comprehensive packages for regulatory compliance.

Flexible Sterilization Cycles

From fractional to full cycles with EtO residual testing.

Robust Qualification

Secure with 2X qualification.

Choice of PCDs

Tailored to your sterilization needs.

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