How Do You Practice Proper Autoclave Safety?
It’s easy to view an autoclave as just another piece of lab equipment, but beneath its sturdy exterior lies a device operating on the knife-edge of physics. The truth is stark: autoclaves are powerful pressure vessels that can turn a minor mechanical issue—a faulty seal or a loose lock—into a catastrophic, even fatal, event. So to prevent this from happening, you need a plan. And in this article, we’d like to offer some help with that. We’re going to go over some example cases, some of the steps listed by various sources, and the overall guide on answering the question of: “How Do You Practice Proper Autoclave Safety?”
Why is Autoclave Safety So Important?
The answer to this may seem simple. But to truly answer it, you have to look at the hard facts. Autoclaves are not your run of the mill machine. They operate under high amounts of pressure in a volume small enough to weaponize the very air it creates if something goes wrong. Something that can turn the smallest issue into a potentially fatal encounter. A faulty door seal, a malfunctioning door lock, you name it. One faulty part and your normal sterilization cycle turns into a catastrophic event.
That sounds extreme, yes. But given the numerous cases of people who have run into issues like this… This is the most apt description. We stress autoclave safety so highly because we deal with them everyday. We see how people properly, or improperly operate them. And it’s our job to make sure that this kind of thing doesn’t happen to you. By teaching you, by fixing these problems and showing you what went wrong and how to prevent it. We’ve made a living from offering the utmost transparency in even the simplest phone calls. Because one day it can potentially save your life or the lives of those around you.
But if you want to see the facts of the matter, let’s look at some of these cases. Some of the unlucky victims of the autoclave’s potentially volatile nature.
The Cases
The Water Bottle
A recent autoclave incident occurred in June 2024 when a laboratory worker attempted to remove a bottle containing water from an autoclave cycle. Although the sterilization cycle was complete, the worker did not allow the chamber and the contents to cool sufficiently. Upon opening the autoclave and removing the bottle, the superheated water inside the bottle immediately flashed into steam and violently splashed out. This rapid expansion was caused by the sudden release of pressure from the bottle being pulled out of the pressurized and hot environment of the autoclave chamber.
The worker was not wearing the necessary heat-resistant gloves and protective apron, resulting in minor burns to their hands and abdomen from the splashing superheated water. The key lesson highlighted by this incident is the critical need for users to wait until both the autoclave chamber and its contents have cooled completely—and confirmed by temperature indicators—before attempting to handle or remove items. This ensures that any superheated liquids inside the containers cannot violently erupt upon exposure to ambient pressure.
Textron Aviation – “Autoclave 8”
The other incident we’re talking about involved a major explosion on December 27, 2019, at the Textron Aviation plant in Wichita, Kansas. It involves a huge industrial autoclave used in manufacturing aircraft parts. This wasn’t just a small lab machine; it was a massive, 64-foot-tall vessel, known as Autoclave 8 used to cure materials under intense heat and liquid nitrogen pressure.
Large industrial autoclaves are necessary for aerospace manufacturers like Textron primarily because they must cure massive, single-piece composite structures, such as wing sections, which simply will not fit into smaller machines. The intense, uniform pressure and heat generated by these huge machines help ensure that the final aircraft has the required lightweight strength and durability for flight safety.
On that day, the autoclave suffered a catastrophic failure due to metal fatigue on its large end cap, and the pressurized contents violently erupted. The resulting blast was incredibly powerful, launching a two-ton piece of the machine over 600 feet away and seriously injuring fifteen different people who were working nearby.
OSHA later investigated and officially cited Textron, essentially saying the company hadn’t done enough to protect its workers from this kind of explosion hazard, pointing to maintenance issues on the huge pressure vessel.
The Common Ground
We should briefly touch on one thing before we move on, but to do that, we have to ask a question: what’s the link? Both of these cases presented to you, while not leading to the unfortunate demise of the people involved, share causation. A lack of proper personal protection led to injury. A lack of proper autoclave maintenance lead to injury.
Both issues were preventable, but happened due to something they both lacked. Something that should be standard when it comes to proper autoclave operation.
What Are the Steps You Can Take?
It may seem like a hard pill to swallow, the dangers of improper autoclave safety. But thankfully, it’s not. In a medical practice, standards and protocol will be your first line of defense when it comes to autoclave safety. And with all of the tools at your disposal in the workplace, there are many ways to protect yourself and prevent an incident. There’s also various do’s and don’ts that will help you fill in more of the gaps. So let’s talk about the various steps that you can take to keep yourself and those around you safe, and to school you on what you need to know about proper autoclave operation.
Personal Protection
While this section does cover PPE, or personal protection equipment, the title is a general umbrella of things. That being both the equipment you wear, and the actions you take. All of them indicative of what proper personal protection should look like.
- Wearing appropriate Personal Protective Equipment (PPE), including a lab coat, heat-resistant gloves, and eye protection, especially when unloading the autoclave. (Protect yourself from heat and steam.)
- Never sealing containers; under pressure, they pose an explosion risk. (Always leave caps loose or use steam-penetrable closures.)
- Never opening the door to the autoclave if there is water running out the bottom. (This means there’s a serious clog or malfunction and scalding water could be present.)
- Waiting for the pressure to reach zero and the temperature is at or below 250°F before opening the door at the end of a cycle. Also, do not stand directly in front of the door. (This prevents severe steam burns and glassware from shattering.)
- Never superheating liquids. (Superheating means the liquid is dangerously hot but not bubbling; any disturbance can cause it to violently spray or explode out of the container.)
Things You Should Never Autoclave (The Don’ts)
- Sharps: Dispose of sharps (needles, broken glass, etc.) directly into a sharps container. Autoclaving is unnecessary.
- Hazardous chemicals: Do not autoclave flammable, reactive, corrosive, or toxic chemicals (e.g., alcohols, formalin, chloroform). Chemically contaminated lab coats must be professionally cleaned or disposed of as chemical waste.
- Dried bleach and bleach-associated materials, or nitrocellulose; both compounds pose a fire or explosion risk.
- Radioactive materials: Contact the DRS Radiation Safety Program for proper disposal.
- Pathological waste: This includes animal and human tissues/organs. Certain types require incineration according to policy.
Properly Prepping Materials
- Pack loosely: For adequate steam penetration, do not compact waste or overfill bags.
- Use proper pans: Place all bags and containers in a large, leak-proof, non-glass, shallow pan (like stainless steel or specific plastics) to contain any spills.
- Open the tops: Open bags/containers before processing so steam can fully penetrate the contents for effective sterilization. You can add a small amount of water to aid heat transfer.
- Check liquids: Use non-glass containers and place them in a pan with water to prevent heat shock. Do not fill containers to the top; leave plenty of headspace. If using screw-caps, ensure they are nearly unscrewed to prevent an explosion.
Instructions for Basic Operation
These are the basic steps; the framework for what to look for when you operate your autoclave daily. These steps are the things you should be doing before, during, and after running your autoclave. Whether it’s for the first time, or after prolonged use.
- Read the Manual: These are basic steps; always read the manufacturer’s specific instructions and receive hands-on training.
- Load and Check: Place items in the chamber and confirm the drain screen is not blocked.
- Use the Right Water: Always be sure to use distilled water to avoid any damage to the autoclave that can lead to malfunctions.
- Select Settings: Close the door and select the load type based on the load you need.
- Time and Temp: Ensure that the timer and temperature are all correct for proper sterilization.
- Run and Log: Start the cycle and fill out the autoclave log if required.
- Unload Safely: At completion, put on your PPE (heat-resistant gloves are key). Open the door slowly and only slightly to let steam escape, and let items cool in the autoclave for at least 10 minutes before removal.
- Verify Results: Check the autoclave tape (color change) and the print-out to confirm the required time and temperature were attained. If not, re-autoclave the load.
Completing all of these steps properly can help you ensure that the sterilization cycle goes smoothly. But cataloguing data can also help you spot any inconsistencies and root out any potential errors. That way, the issue can be dealt with before it becomes a much bigger problem. But there’s one other important step that we thought deserved its own step, one that, like the others, is vitally important; preventative maintenance.
Why is Preventative Maintenance Important?
The other big factor in autoclave safety, is properly maintaining your unit; preventative maintenance. Upkeep on your autoclave is so very important. Not only will it keep it working and up to standard, but these aren’t cheap throwaway machines. Autoclaves for any practice, big or small, are an investment. Meaning this isn’t something you window shop for like you’re browsing the Walmart aisle.
Your practice has very specific needs that vary down to the most specific of factors. If anything goes wrong, then you’ll have such a headache trying to figure out where you went wrong and you’ll start regretting every buying it. So to save you the headache of a potential problem, let’s go over some of the reasons why preventative maintenance can save you and your practice. We can talk about maintenance all day every day (because we already do.) But let’s just go over a few of the main benefits for why preventative maintenance should be in your schedule:
- Optimal Performance and Functionality – When your autoclave is properly maintained, the efficacy of the sterilization remains. Any issues stemming from improper maintenance can lead to an unsterile cycle.
- Extending the Lifespan of Your Autoclave – Proper maintenance can help clean and replaced dirty or damaged parts, when if not replaced, can cause problems to the overall unit, tanking the lifespan.
- Enhancing Workplace Safety – As we mentioned above, ensuring your autoclave is properly maintained can reduce the risk of injury and fatal encounters for you and those around you.
- Meeting the Industry Standards – Industry standards require that your autoclave be able to sterilize at a certain level for proper decontamination. Preventative maintenance exists to ensure that your unit continues to meet those standards.
- Giving Peace of Mind – When your unit isn’t constantly firing back errors or creating a hazard in your workplace, the peace of mind offered with the help of preventative maintenance is unparalleled. No need to worry about any future problems when you take care of the on time.
If you’d like to read more about preventative maintenance though, check out our blog on it here.
Final Thoughts
Ultimately, autoclave safety boils down to a clear understanding of risk and responsibility. The incidents we reviewed, from minor superheated liquid burns to catastrophic structural failure, all share the same preventable causes: operator error and maintenance neglect.
By consistently applying Personal Protective Equipment (PPE), strictly adhering to the cool-down and depressurization protocols when unloading, and prioritizing scheduled preventative maintenance, you are managing the risk proactively. These steps not only extend the life of your equipment and meet compliance standards but, most critically, they guarantee the safe use of an essential, yet inherently volatile, piece of technology, ensuring peace of mind for everyone in the lab.
So when it comes to proper autoclave safety, Sterilizer Autoclave Solutions is here to help. And if you have any questions about autoclave safety, personal protection equipment, or anything else, please give us a call at 704-966-1650, and we’ll get you where you need to go.
As always if you have any questions about this process or anything else please feel free to contact us and take advantage of our “FREE TECH SUPPORT.”
We also offer FREE VIRTUAL TECH SUPPORT to “See and Talk” with a “Real Time Live Technician” for any problems you may be in need of help with.
You can also use our “FREE MAINTENANCE PROGRAM”. Take the guesswork and worrying about what unit is due for maintenance and which maintenance cycle it is time for. We will keep track of all your autoclaves and let you know when it’s time for anything.