Rethink the Approach
Achieving sterility by using autoclaves is a difficult and sometimes delicate process. This delicacy of the process requires a significant investment in autoclave equipment, and maximizing the value of that initial investment is a great way to protect your facility’s assets. Refurbished autoclaves are a great way to maximize the lifetime value of investments in autoclaves.
In this article, we’ll define a new solution for refurbished autoclaves through a service we call Control Upgrades or Control Rebuilds. Deciding between these two methods is based on an inspection of the piping system (piping and valves) coupled with a discussion about autoclave performance issues.
In a significant percentage of situations where an autoclave is performing suboptimally, an aging control system has been at the root of the system. This fact is the focal point of our new approach to delivering a refurbished autoclave.
Refurbished Autoclaves vs.
Control Upgrades vs. Control Rebuilds
Traditional methods for refurbishing autoclaves typically involve the removal of an entire unit from the field for refurbishing at the manufacturer’s factory. You’re probably familiar with the process: remove an autoclave with performance issues from the lab, ship the unit to a manufacturer’s facility, complete the inspection process, make modifications, and then sell or reinstall the unit back into the laboratory. There are several problems with this method:
- Significant downtime and cost: There is the potential for significant downtime and cost involved in shipping units from laboratory locations to the manufacturer’s factory.
- Limited availability: If you’re purchasing a newly refurbished autoclave not originally from your facility, you are beholden to manufacturer availability. This availability can be limited with rapid changes in availability.
- Facility disruption: removal and reinstallation of an existing autoclave can bring several days of disruption to a facility’s operations during both the removal and/or installation of the refurbished autoclave.
This is why we’ve developed Control Upgrades and Control Rebuilds as alternatives to a traditional refurbished autoclave. Simply put, these methods are a customer-proven process to refurbish an autoclave in the existing space. If an autoclave inspection determines that the piping system (piping and valves) has years of existing usable life left, we recommend a Control Upgrade to bring updated functionality, monitoring, and troubleshooting to the autoclave. If only the chamber and jacket have usable life, a Control Rebuild is recommended to refurbish the autoclave. Both of these methods are done onsite, minimizing downtime and costs associated with shipping, ensuring the availability of a refurbished autoclave, and minimizing disruption.
Can Control Upgrades and Rebuilds from Beta Star be completed only on Beta Star autoclaves?
No! We’ve completed control upgrades and rebuilds on a variety of manufacturers’ autoclaves.
Control Upgrade and Rebuild Process
(for In-Lab Refurbished Autoclaves)
Refurbished Autoclaves Require a Chamber with Structural Integrity
The first step in the refurbished autoclave consideration process is an evaluation of the chamber and jacket. These core components make up a significant percentage of a new autoclave investment. If they are not able to be a part of a refurbished autoclave, then investing in a new autoclave is more cost-efficient. The age of the autoclave chamber, current condition, and water quality are three of the main evaluation points.
Age of the Chamber
Evaluating the age of the chamber requires an understanding of one number: 15. As in, 15 years. That number, for most autoclave manufacturers and sizes, is the standard chamber warranty.
Now, refurbishing an autoclave will void most, if not all, chamber warranties from the original manufacturer. But, this number gives insight into the confidence in the durability of the chamber through 15 years.
Current Condition
During the chamber condition process, technicians conduct a thorough inspection to check for any early signs of chamber corrosion potentially caused by corrosive autoclave loads and water quality. In addition, chamber sealing needs to be confirmed to ensure the door and chamber mechanism function as they should. Lastly, any weld seams along the chamber will be carefully examined.
Water Quality
If any hints of corrosion are detected, water quality tests may need to be conducted. The presence of water impurities will reduce the expected lifespan of the chamber. Water quality tests may be required if rouge (staining of the chamber) or hints of corrosion are detected during inspection.
Evaluating the Piping System with the Control System
After the chamber, an inspection of the piping system (piping and valves) is conducted to determine the estimated remaining life expectancy. At this stage, the experience of the technician is vital. This evaluation is best completed with years of experience analyzing piping systems while learning the warning signs as end-of-usable life approaches.
At the end of this evaluation, the condition of the piping system determines whether the Control Upgrade (replacing only the control system) or Control Rebuild (replacing the control and piping systems) is the recommended method.
Control Upgrades/Rebuilds vs. New: Why Go with the In-Lab Refurbished Autoclave Route?
The first (and arguably most important) reason to consider refurbishment is that it is a cost-effective solution for facilities looking to upgrade their sterilization equipment. Depending on the inspection, refurbished autoclaves are available at a fraction of the cost of a new unit. By choosing a refurbished autoclave, facilities can save significant amounts of money that can be used for other critical operations.
Secondly, the Control Upgrade/Rebuild route minimizes facility disruption. Acquiring a new autoclave can be a time-consuming process that involves extensive planning, installation, and validation (depending on the lab). In contrast, the Control Upgrade can be completed in as little as three days, minimizing downtime and reducing the impact on facility operations. This approach is especially important for facilities that cannot afford to shut down for extended periods of time.
Thirdly, purchasing new autoclaves can create a significant amount of unnecessary waste. When a facility replaces an autoclave, unit components are recycled when possible, but the remainder of the unit ends up in a landfill. The analysis completed ensures the lifespan of the chamber, jacket, and piping systems are maximized. This approach is not only environmentally responsible but also financially sustainable, as it requires investment only for the components that are at their end of life.