Instrument Reprocessing for Universities: Solutions for Teaching, Research, and Clinical Practice

Challenge: High patient volume in a limited space

Founded in 2012, Danube Private University combines modern dental education and clinical patient care under one roof. Each semester, 48 students are enrolled in the program, while approximately 200 students are present at the clinic each day. At 48 treatment stations, up to 400 to 500 patients are treated each day. The demands on the availability of hygienically reprocessed instruments are correspondingly high.

Before planning the reprocessing system, a fundamental decision had to be made: Should the university reprocess its instruments in-house or use the large external reprocessing service provider in Krems? An external solution, however, would have meant additional transport routes, longer turnaround times, and greater dependence on fixed pickup and delivery cycles. For the treatment courses, on the other hand, it was crucial that instruments be made available again quickly, reliably, and in sufficient quantities.

Solution: A High-Performance Central AEMP

Danube Private University therefore opted for its own central medical device reprocessing unit (AEMP). The solution combines high capacity with efficient, clearly structured processes—all within the most compact footprint possible.

Five MELAtherm thermal disinfectors and three ultrasonic cleaners enable the rapid cleaning and disinfection of large quantities of instruments. The instruments are then packaged using two MELAseal Pro sealing machines or in a stock of approximately 1,000 sterilization containers. For sterilization, four Vacuklav 40 B+ units, each with an 18-liter chamber volume, and one Cliniclave 45 with a 100-liter chamber are available. The combination of several compact autoclaves and one large autoclave allows for flexible adaptation to varying loads and peak utilization.

MELAtrace is used to electronically document and release the reprocessing procedures. MELAprint 60 handles the labeling of instruments and sets. This creates a seamless, traceable workflow—from cleaning and disinfection through packaging and sterilization to documented release. The department’s own AEMP thus lays the foundation for independent processes, short instrument turnaround times, and reliable conditions for learning and treatment.

As part of a comprehensive modernization project, the University of Sarajevo planned to revamp its dental clinic. With 159 treatment stations and approximately 200 students per semester, large quantities of instruments must be reliably reprocessed every day in a short amount of time. During the initial planning phase, the focus was primarily on the treatment concept. However, future requirements for instrument reprocessing had not yet been sufficiently taken into account.

Decentralized reprocessing directly in the individual treatment areas would have led to inconsistent workflows, a high level of manual effort, and limited capacity given the scale of the operation. Together with MELAG, the university therefore developed a needs-based approach: a shift from decentralized processes to a central reprocessing unit for medical devices. The new hygiene workflow was designed to enable high throughput while remaining flexible enough to adapt to varying instrument volumes and loading conditions.

From Existing Space to Central AEMP

A particular challenge was integrating the new reprocessing facility into the existing building structure. A former conference room and two storage rooms were redesigned for this purpose into a clearly separated two-room concept. In the non-clean area, eight thermal disinfectors handle the mechanical cleaning and disinfection of the instruments. The reprocessed instruments are then transferred to the clean area, where packaging, sterilization, release, and distribution take place.

For sterilization, the University of Sarajevo relies on a combination of eight Vacuclave autoclaves and three models from the Cliniclave series. The different chamber sizes allow for flexible loading, short cycle times, and distribution of instrument quantities based on demand. This enables both smaller loads and extensive instrument sets to be sterilized efficiently.

In addition, approximately 700 MELAstore trays and boxes are in use. They reduce manual steps, simplify transport between treatment and reprocessing, and support a standardized instrument cycle. In this way, a high-performance central AEMP was created from limited floor space, meeting the high demands of both teaching and patient care.

The projects at Danube Private University, the University of Sarajevo, and the Arab Academy demonstrate that effective instrument reprocessing does not result solely from the selection of individual devices. What is crucial is a comprehensive concept that takes into account spatial conditions, the volume of instruments, treatment procedures, and future capacity requirements from the very beginning.

The earlier instrument reprocessing is incorporated into the university hospital’s planning, the better the layout, workflow, and hygiene processes can be coordinated. In doing so, the focus should not be limited to individual process steps such as cleaning, packaging, or sterilization. Only the interaction of all work steps—from the return of contaminated instruments to documented release—creates a safe and efficient instrument cycle.

Equally important is flexible equipment configuration. The combination of different equipment capacities makes it possible to reprocess both small loads and large quantities of instruments as needed. Multiple units that can be operated in parallel also increase availability, shorten turnaround times, and minimize the impact of potential outages. Innovative and optimally sized solutions can also limit the long-term costs associated with maintenance, validation, and repairs.

A reliable service partner is a key factor for success in this regard. Professional installation, regular maintenance, rapid technical support, and ongoing training ensure that the planned processes are implemented safely even during daily operations.

The most important insight from the university projects is therefore this: Early, comprehensive, and flexible planning lays the foundation for maximum process reliability, short instrument turnaround times, and consistently reliable conditions for teaching and patient care.