Using Sterilization Reels Across Different Sterilization Methods

Few packaging formats match the versatility of Sterilization Reels. Reels, supplied as continuous paper/film or Tyvek®/film tube, allow you to cut custom lengths, seal both ends, and create a bag exactly the size of the device. Made well, reels streamline inventory, reduce waste, and maintain a reliable sterile barrier across multiple sterilization modalities. Below is a modality-by-modality manual, plus practical sealing and validation tips, and how reels complement sterilization bags in an overall sterile processing strategy.

What sterilization reels are (and are not)

A sterilization reel is a continous porous tube (typically medical paper/clear film or Tyvek®/film) printed with process indicators and seal tracks. A package is created by heat sealing one end, putting the device inside through the open end, and then sealing the open end as well. Reels are ideal for variable lengths (endoscopes, long forceps) and mixed kit sizes without having to stock dozens of bag SKUs. They are single-use sterile barriers; Never reseal or reuse a segment.

Appropriate mode: choosing the right sterilization reel for the job

1) Steam (Autoclave, 121–134 °C)

• Best Fit: Paper/film sterilization reels designed for steam.
• Why it works: The calibrated porosity of medical paper allows for steam entry and drying; The film provides visibility and a clean peel path.
• How to be successful: 

1. Leave uniform clearance for condensate drainage and steam circulation.
2. Load edge-on with paper side up and film side down (if validated) to promote drying.Loading with the paper side facing up (or film side down) takes advantage of gravity. Condensation that forms on the clear film, which is less absorbent than the paper, will naturally run off and be absorbed by the paper below
3. Target for sturdy, peelable seals (≥6mm band) that opens without tearing the paper.

•  What to avoid: Long, dense loads that consistently produce wet packages; consider double bags (bag within a bag) or inner trays to create air flow.

2) Ethylene oxide (EO)

• Best choice: paper/film reels or film/Tyvek® reels for heavy or sharp sets.
• Why it works: Porous substrates allow pre-conditioning, EO penetration and aeration; Tyvek® adds puncture resistance and low lint.
• How to be successful:

1. Respect the pre-conditioning humidity and total aeration; Residual EO can make coatings brittle over time.
2. Keep labels away from porous areas and seal tracks to prevent obstruction of gas flow.

• Pro Move: For long-life or moisture-sensitive products, use an outer EO-compatible header pouch (aluminum/film body + Tyvek® header) over a reel-made inner pack.

3) Vaporized Hydrogen Peroxide (VHP) / Plasma

• Best fit: Tyvek®/film sterilization reels (not paper/film).
• Why it works: Tyvek® does not react with peroxide like many papers do; preserves sterilant activity and allows rapid aeration.
• How to be successful:

1. Validate indicator inks, coating systems, and print locations for oxidative exposure.
2. Avoid heavy ink coat on the face of Tyvek®; Keep seals flat and wrinkle-free.

4) Low Temperature Steam Formaldehyde (LTSF)

• Best fit: Paper/film rolls explicitly qualified for LTSF (moisture resistant papers, compatible coatings).
• Risks: High humidity and formaldehyde stress paper fibers and seals; Quick vacuum ramps can inflate bags.To prevent ballooning, sterilization cycles should be run according to validated parameters, and loads should not be overfilled, to ensure the vacuum is applied gradually and evenly. Some autoclaves have systems designed to prevent this issue by precisely controlling the vacuum and pressure.
• How to be successful: 

1. Use LTSF-validated paper grades; Add headroom, smoothen out vent profiles (In Low-Temperature Steam Formaldehyde (LTSF) sterilization, “vent profiles” refer to the carefully controlled sequence and rate of vacuum and atmospheric air pulses used to evacuate formaldehyde gas and steam from the chamber at the end of the cycle. A well-engineered vent profile is essential for preventing damage to pouches and for removing toxic sterilant residues), and edge load to prevent condensation from building up.
2. Inspect corners and seals of packages after cycle; Throw away any wrinkled or damp packages.

5) Radiation (gamma, electron beam, X-rays)

• Better fit: Film/Tyvek® reels are often radiation tolerant; The paper/film may yellow or become brittle depending on the dosage.
• Reality check: Reels are less common here because radiation is frequently applied to pre-made sterilization bags or tray/lid systems. If using spools,dose- map the shipper, confirm the seal strength after dosing, and recheck the peel and particulate after aging. (Using reels of packaging materials in gamma sterilization requires a comprehensive validation process that extends beyond a standard pouch. Since gamma radiation can alter polymer properties over time, the validation must ensure the packaging remains sterile and functional throughout its claimed shelf life).

6) Emerging gases (NO₂, ClO₂)

• Best fit: Tyvek®/film rolls due to chemical compatibility and porosity.
• Caution: Validate interactions with inks, labels, and adhesives; Some dyes are reactive.

Reels vs. Sterilization Bags: When to Choose Which

• Choose sterilization reels for variable lengths, long instruments, or frequent size changes. You will minimize waste and SKU counts while maintaining validated seals.
• Choose sterilization pouches for high volumes and repeatable sizes where speed and convenience outweigh the flexibility of cutting to size.  In many CSSDs and medical device plants, both are used: reels for odd sizes and long items; pouches for Standard items.

Sealing and handling: build a Peel that travels

• Lock a sealing window. Validate the temperature/pressure/dwell (or belt speed) for each laminate. Too little peel strength → channel leaks; too much → fiber/ lint generation and hard peel chevron seals.
• Aim for ≥6mm seals (or dual bands) on heavier/sharper loads; Ensure planarity of the jaw so that the band is uniform from end to end.
• Aim for perfection in seal tracks. Oils, fibers and inks create microchannels. Clean straps/jaws every shift; Keep the indicator print away from the seal tracks.
• Proper size for each package. Leave 20-50mm beyond the longest element for airflow inside the pouch; Never bridge instruments over the seal. An instrument that extends into the sealing area can interfere with the sealing process and create a channel for microorganisms and other contaminants to enter. Any portion of the instrument that is trapped within the seal may not be fully exposed to the sterilant (e.g., steam, ethylene oxide). Heavy or sharp instruments “bridging” the seal can exert pressure on the packaging during sterilization and handling. Presenting the instrument correctly without touching the non-sterile edges of the package becomes difficult, increasing the risk of contamination. 
• Protects sharp geometry. Use tip protectors, backing cards or internal trays so that the edges do not wear down the substrate during pressure changes.
• Smart tag. Place the UDI/lot labels on the film side, outside of the seal lines and outside of the pore field. Use internal indicators for dense or opaque content.

Validation and monitoring: what auditors expect

Anchor your program to ISO 11607-1/-2 (material suitability and process validation) and EN 868 (requirements for papers, Tyvek®, bags/reels). A pragmatic plan includes:

• Peeling resistance: ASTM F88: Press window “hard enough to ship, easy enough to peel.”
• Integrity: ASTM F1929/F3039 (tint) or F2096 (bubble) to detect channels that the eye cannot see.
• Distribution and aging: ASTM D4169/ISTA plus ASTM F1980 (accelerated aging) to confirm seals survive actual logistics and shelf life.
• Aseptic Usability: Users with post-aged gloves should open them without spilling or touching contamination.

Common mistakes (and quick fixes)

• Wet packages after steaming: Increase headroom, orient paper up/film down (if validated), and avoid tight, flat stacks.
• Residual EO odor: expand aeration; Check that labels/inks do not clog pore spaces.
• VHP failures with paper/film: Switch to Tyvek®/film rolls validated for oxidative cycles.
• Corner tears in LTSF: Use moisture resistant papers, smooth vacuum ramps, and edge load.
• Random channel leaks: Clean bands/jaws of sealant; check the width and flatness of the seal; Keep graphics out of seal tracks.

Conclusion

Sterilization reels are a powerful and flexible platform when you align substrate choice with modality, design repeatable seals, and validate integrity, distribution, and shelf life. Used in conjunction with sterilization bags, the reels help medical packaging teams around the world control costs and complexity without compromising aseptic presentation, so that each instrument arrives at the point of use sterile, visible and easy to open.