Why hydrogen-peroxide plasma needs Tyvek®, not paper
Paper absorbs hydrogen peroxide and can abort plasma cycles. How to choose Tyvek®-film reels, plasma indicators and loading practice for H₂O₂ sterilization.
In short: hydrogen-peroxide gas plasma cycles need cellulose-free packaging. Paper absorbs hydrogen peroxide, which can lower its concentration in the chamber and cause the cycle to abort. Use Tyvek®-film reels or pouches (or approved polypropylene wraps), plasma-specific indicators, and no linen, gauze or paper labels in the load.
Why paper does not work in plasma
Low-temperature hydrogen-peroxide gas plasma sterilizers inject a measured dose of hydrogen peroxide into a deep vacuum. Cellulose — paper, cotton, gauze, linen and cardboard — absorbs the peroxide. That reduces the amount available to sterilize the devices, and most systems will cancel the cycle when they detect it. Even when a cycle completes, absorbed peroxide in packaging is not acceptable.
What Tyvek® is
Tyvek® is DuPont™’s flashspun high-density polyethylene. It contains no cellulose, lets the sterilant through, and forms a strong microbial barrier. In reels and pouches it replaces the paper side and is sealed to a transparent PET film so the device stays visible. It is also widely used for ethylene-oxide sterilization.
Choosing a Tyvek® reel
- Process compatibility. Confirm the reel is declared for H₂O₂ plasma and, if you also run EO, for EO.
- Standards. Look for conformity to EN 868-5 and ISO 11607-1, made under ISO 13485.
- Process indicator. The reel should carry a printed plasma indicator that changes visibly in the cycle.
- Width. Leave room for the device plus a clear margin to each seal; tight packs stress the Tyvek®-film seal.
- Sealer settings. Tyvek®-film seals usually need a different temperature from paper-film; follow the manufacturer’s figure and validate it.
The SteriCraft® Tyvek plasma sterilization reel uses two-layer Tyvek® 2FS™ with peelable PET film, in widths from 50 to 400 mm.
Indicators for plasma cycles
Steam indicators do not respond correctly to hydrogen peroxide. Use plasma indicator tape outside wrapped packs and Class 4 plasma indicator strips inside packs. The SteriCraft® plasma indicator strips change from green to yellow, and plasma indicator tape closes and marks the pack.
Loading tips
- Devices must be clean and fully dry; moisture can also abort a plasma cycle.
- Check the sterilizer manufacturer’s limits for lumen length and diameter.
- Do not stack pouches flat on top of each other; stand them on edge with space for the sterilant to circulate.
- Remove any paper labels, cotton ties or foam from the load.