As hospitals and healthcare providers adopt more sustainable practices, the reprocessing of reusable medical devices has become standard. This process reduces waste, lowers costs and extends the life of specialized instruments like endoscopes. The Association of Medical Device Reprocessors (AMDR) estimates that reprocessed devices are now used in more than 10,500 hospitals worldwide—a number that continues to grow as healthcare systems look for ways to improve efficiency without compromising safety.
However, these benefits come with new challenges—particularly when chemical disinfectants release harmful vapors into the air. Disinfectants such as peracetic acid (PAA) are highly effective, but even low-level exposure to airborne PAA can create health risks in rooms that operate continuously. Monitoring these concentrations is key to maintaining safe working conditions for staff and meeting occupational safety standards.
What is Medical Reprocessing?
Medical reprocessing is the process of cleaning, disinfecting and sterilizing reusable equipment, allowing it to be safely put back into service. These procedures are essential in maintaining risk-free treatment and aim to prevent the transmission of infection. Due to infection control protocols, strict standards and guidelines are in place to preserve the effectiveness of reprocessing. Procedures commonly include several different steps to meet safety standards and comply with regulatory requirements.
The reprocessing of reusable medical equipment involves the following steps:
- Cleaning: Using manual or automated washing protocols to remove visible soiling and organic matter, such as blood and tissue.
- Disinfecting: Killing or inactivating micro-organisms on device surfaces with the use of chemical disinfectants such as peracetic acid, ethylene oxide and hydrogen peroxide.
- Sanitizing: Destroying all micro-organisms, including spores that remain on the instruments. This can be completed via autoclave (steam cleaning), dry heat, gas sterilization or radiation.
- Testing: Checking for damage, cleanliness and proper function.
- Packaging and labelling: Appropriately packaging reprocessed devices to maintain sterility.
- Storing: Storing packaged instruments in a controlled environment to prevent recontamination.
The Role—and Risks—of Peracetic Acid
Peracetic acid is a preferred sterilant in healthcare due to its fast action, residue-free nature and ability to disinfect even in the presence of organic matter. It’s particularly useful for sterilizing heat-sensitive devices like endoscopes, which cannot be autoclaved.
However, PAA is a highly reactive compound that can cause health issues when inhaled. Over time, leaks or improper ventilation can lead to elevated vapor levels in reprocessing areas. Staff exposed to PAA may experience:
- Irritation of the eyes, nose, throat or skin
- Coughing, shortness of breath or asthma-like symptoms
- Long-term damage to respiratory function
- Pulmonary edema or organ stress in severe cases
Because PAA has a sharp vinegar-like odor, it’s possible for staff to become desensitized over time—making it difficult to rely on smell alone as an indicator of danger.
Health and Safety Compliance
Occupational health regulations require employers to prevent or limit exposure to hazardous substances. In the UK, COSHH (Control of Substances Hazardous to Health) mandates that facilities implement control measures to reduce risks when using chemicals like PAA.
Similarly, the American Conference of Governmental Industrial Hygienists (ACGIH) recommends a short-term exposure limit of 0.4 ppm over a 15-minute period. To meet these standards, healthcare facilities are increasingly turning to continuous gas monitoring systems to detect leaks, track exposure levels and provide documented proof of compliance.
Gas Monitoring Solutions
As a leading provider of smart gas sensor technology, Badger Meter is one of the few global manufacturers to offer a sensor specifically for the detection of PAA. Available through our BlueEdge™ portfolio, these electrochemical sensors are compatible with the F12 and D12 Fixed Toxic Gas Detectors and the handheld D16 Portasens Leak Detector. They provide hospitals and medical facilities with a range of reliable and trusted solutions for maintaining safety standards within contamination rooms and protecting the health and well-being of site personnel.
On a recent project, experts at Badger Meter successfully delivered a state-of-the-art solution for the continuous monitoring of PAA in endoscopy suites at many hospitals within the United Kingdom. The system, comprising the F12D with a PAA sensor, detects and reports on PAA levels during reprocessing procedures, sending visual and audible alerts if levels are exceeded. This provides peace of mind to operators that the working environment remains safe with a minimal risk of over-exposure.
With a number of different installation options and sensor configurations, the F12D offers a versatile solution that can be positioned virtually anywhere in a room to meet the individual needs of an application. Using pre-calibrated smart sensors, the system requires minimal maintenance and is simple to use. With a built-in data logger, the detector is able to capture historical data that can then be used to investigate claims of exposure. In the event that the device detects unsafe levels of PAA vapor in the air, an alarm would be triggered, allowing staff to be safely evacuated and the room to be sealed until it is once again safe. To further enhance the solution, the Badger Meter D16 PortaSens Leak Detector could be used to check that the gas has dissipated prior to staff re-entry.
Final Thoughts
Reprocessing suites are often in constant use, meaning that even trace levels of airborne PAA can accumulate and pose risks to staff. Without reliable gas detection, it’s difficult to confirm whether air quality meets safety standards—especially when personnel may no longer notice the smell due to frequent exposure.
To address these challenges, organizations like the UK’s Joint Advisory Group on GI Endoscopy (JAG) now require hospitals to demonstrate that PAA levels in breathable air remain within recommended limits. Their audit process encourages the use of portable leak detectors like the D16 PortaSens and fixed monitoring systems like the F12 to support ongoing safety and compliance.
Badger Meter solutions help healthcare facilities monitor air quality in real time, respond quickly to elevated PAA levels and maintain safe working environments for medical staff—supporting the long-term success of modern reprocessing operations.
