Instrument reprocessing for universities: solutions for teaching, research and clinical practice

As part of a comprehensive modernisation project, the University of Sarajevo planned to reorganise its dental clinic. With 159 treatment stations and around 200 students per semester, large quantities of instruments need to be reprocessed reliably and quickly every day. During the initial planning stage, the focus was primarily on the treatment concept. However, the future requirements for instrument reprocessing had not yet been adequately taken into account.

Decentralised reprocessing directly within the individual treatment areas would, on this scale, have led to inconsistent procedures, a high level of manual effort and limited capacity. Together with MELAG, the university therefore developed a needs-based approach: a shift from decentralised processes to a central reprocessing unit for medical devices. The new hygiene workflow was designed to enable high throughput whilst remaining flexible enough to cope with varying volumes of instruments and loading situations.

From an existing room to a central AEMP

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

For sterilisation, 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 the distribution of instrument quantities according to demand. This means that both smaller loads and extensive instrument sets can be sterilised efficiently.

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

Challenge: High student numbers in a limited space

Founded in 2012, Danube Private University combines modern dental training and clinical patient care under one roof. Each semester, 48 students are trained, whilst around 200 students are present in the clinic every day. Up to 400 to 500 patients are treated each day across 48 treatment stations. 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 based in Krems? However, an external solution would have meant additional transport routes, longer turnaround times and greater dependence on fixed collection and delivery cycles. For the treatment courses, on the other hand, it was crucial that instruments were 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 as compact a footprint as possible.

Five MELAtherm thermal disinfectors and three ultrasonic cleaners enable the rapid cleaning and disinfection of large quantities of instruments. The instruments are then packed using two MELAseal Pro sealing machines or into a stock of around 1,000 sterilisation containers. Four Vacuklav 40 B+ units, each with a chamber volume of 18 litres, and one Cliniclave 45 with a 100-litre chamber are available for sterilisation. The combination of several compact autoclaves and one large autoclave allows for flexible adaptation to varying loads and peak utilisation.

MELAtrace is used to electronically document and authorise the reprocessing procedures. MELAprint 60 handles the labelling of instruments and sets. This creates a seamless, traceable workflow – from cleaning and disinfection through to packaging and sterilisation, right through 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.

The projects at Danube Private University, the University of Sarajevo and the Arab Academy demonstrate that an effective instrument reprocessing system is not achieved simply by selecting individual pieces of equipment. What is crucial is an overall concept that takes into account spatial conditions, the volume of instruments, treatment procedures and future capacity requirements right from the start.

The earlier instrument reprocessing is incorporated into the planning of the university hospital, the better the layout, walking routes and hygiene processes can be coordinated. In doing so, the focus should not be solely on individual process steps such as cleaning, packaging or sterilisation. It is only the interplay of all work steps – from the return of contaminated instruments to their documented release – that creates a safe and efficient instrument cycle.

Equally important is flexible equipment. The combination of different equipment capacities makes it possible to reprocess both small loads and large quantities of instruments as required. Having several pieces of equipment that can be used in parallel also increases availability, shortens turnaround times and reduces the impact of any potential breakdowns. Innovative and optimally sized solutions can also minimise 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 in day-to-day operations.

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