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Sterilisation validation and record keeping: what you have to be able to prove

By Vvon Engineering Team | Published | Updated

Understand process qualification, routine monitoring, load release and instrument traceability, with current moist-heat sterilisation references.

Medical equipment RFQ checklist (TXT)

Sterile-services records should answer three linked questions: was the process qualified for the intended loads, did a specific cycle meet its release criteria, and can the instruments be traced when an investigation is needed? A complete system addresses all three.

This article addresses process-validation responsibilities and the evidence to agree with the responsible team. The traceability article focuses on connecting instruments, batches and records within the CSSD workflow. Related reading: Instrument traceability in a CSSD: what the batch record has to prove.

Qualification is not the same as a service visit

ISO 17665:2024 addresses development, validation and routine control of moist-heat sterilisation processes. EN 285 and EN 13060 address different steam-steriliser equipment scopes, and ISO 15883 addresses washer-disinfectors. Cleaning must be effective and validated where required; a satisfactory cycle printout cannot compensate for inadequate cleaning.

Qualification comes in three parts and all three have to exist on paper.

Define periodic review and requalification requirements, including assessment after repairs or load changes that may affect the validated process. Keep traceable calibration and suitability records for the measurement equipment used; uncertainty and instrument status matter when assessing the evidence.

Routine monitoring and load release

Specify the test schedule for the actual steriliser, cycles and load types. CDC describes daily air-removal testing for dynamic-air-removal steam sterilisers. Leak tests, hollow-load challenge devices and other checks must follow the applicable standard, manufacturer instructions and validated procedure; they are not interchangeable tests required identically on every machine.

Use the required external and internal chemical indicators with the pack and cycle. They show specified process exposures, not that every item is sterile. Interpret them together with physical cycle records, packaging condition and the other release criteria.

Set biological monitoring and implant-load release requirements under the applicable guidance and approved procedure. For example, CDC recommends biological monitoring of loads containing implantable items and quarantine until the result is available whenever possible. A trained, authorised person should review all required evidence before release.

The records that have to survive

Traceability is a chain, and it breaks at whichever link is not written down.

  1. A load number, generated for every cycle and printed on a label on every pack in it.
  2. A load record listing the contents of that cycle, the machine, the cycle type, the date and time, and the operator.
  3. The cycle chart or printout, with the indicator results attached and the release signature on it.
  4. The patient link. Record the set and load in the clinical record so backward and forward tracing support a proportionate investigation or recall.
  5. The supporting logs: feed water and steam quality, planned maintenance, sensor calibration, staff training and competence.

Set retention and access rules with the hospital’s quality and records teams, including implant traceability where applicable. Protect records against loss and fading; verify legible backups of thermal printouts or validated electronic exports rather than relying on one paper copy.

Periodically trace a selected pack back to its load, monitoring results and release decision, and test the forward recall route. Record gaps and corrective actions. A successful traceability exercise is useful evidence but does not by itself guarantee an audit outcome.

Standards reference: ISO 17665:2024.

For the stated monitoring examples: CDC sterilizing practices.

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