Material and Packaging Selection and Compatibility with Chlorine Dioxide Gas Sterilization: Poster Presented at PDA Week 2025.

Abstract

Chlorine dioxide gas (CD) sterilization is an alternative modality to ethylene oxide as well as other sterilization modalities and is of high interest to the EPA and FDA due to both its sustainability as well as effectiveness. The dry method of generating chlorine dioxide gas was developed within Johnson and Johnson and generates a greater than 99% pure form of chlorine dioxide gas. CD gas is an oxidizer which is non-carcinogenic, non-explosive at use concentrations and can perform sterilization at ambient temperature. The presentation will discuss the elements that need to be considered when selecting packaging for a product being sterilized with chlorine dioxide gas. It includes an explanation of what packaging is most suitable for certain product categories as well as packaging suggestions for products with unique restrictions such as absorbable products. The poster will also include expert analysis from material manufacturers on test data on the suitability of chlorine dioxide with their materials. Additionally, residual levels and cytotoxity is analyzed to further indicate compatibility after processing.