If your sterilisation cycles keep getting interrupted by failed leak tests, you’re not alone, and you’re not imagining it.
A lot of medical device manufacturers and hospital facilities are struggling with older autoclaves and sterilisers that just don’t pass leak checks like they used to. But why is this happening, and what’s the best way to fix it without ripping out equipment that still has life left?
Let’s break down what’s really going wrong and how you can prevent it from slowing you down.
Why Older Sterilisation Equipment Starts to Struggle
As autoclaves and sterilisers age, small issues add up. You’re likely seeing problems that include:
Worn Seals: Door gaskets and chamber seals naturally degrade with heat, pressure, and time. Even minor wear can create micro-leaks.
Valve and Venturi Fatigue: Over time, internal valves wear down. A leaky valve may pass unnoticed—until your leak test starts failing more often than not.
Sensor Drift: Pressure sensors lose accuracy slowly, and older units aren’t always calibrated as often as they should be.
Chamber Fatigue: Decades of thermal cycling can cause tiny distortions that disrupt vacuum integrity—even if the chamber still looks sound.
These issues don’t usually cause total failure. But they can throw off leak testing, stop your cycle mid-way, and introduce inconsistencies your QA team can’t afford.
What Happens If You Ignore the Problem?
- More unplanned downtime
- More service calls and frustration
- Risk to validation records and audit readiness
- Delayed sterilisation and backup on the floor
- Uncertainty you can’t afford in regulated environments
But here’s some good news: you don’t have to replace everything. With the right plan, you can keep your equipment running reliably and confidently pass leak checks every time.
5 Ways to Prevent Failures
- Book a Calibration (Not Just a Service Call)
A properly calibrated leak test system is often the difference between passing and failing. At Nolek, we offer traceable calibration visits that keep your sensors honest and your audits stress-free. - Start a Replacement Schedule
You don’t need to replace your whole machine. Just swap out age-sensitive parts like gaskets, valves, and sensors before they become a problem. - Watch for Trends in Your Data
If your cycle times are creeping up or borderline failures are increasing, it’s a signal. Don’t wait, act before it fails completely. - Upgrade the Test System, Not the Steriliser
Still using an outdated leak tester? We can retrofit a modern, validated test module onto your existing unit. - Protect Yourself with a Service Plan
Our customers appreciate the peace of mind that comes with scheduled checks, priority service, and no surprise costs. One call, everything handled.
Why Teams Trust Nolek
We’ve helped MedTech manufacturers and facilities across Europe extend the life of their equipment, pass leak tests first time, and stay ahead of audits. Whether you’re running a single legacy steriliser or managing a fleet, we’ve got the tools, knowledge, and support to keep things smooth.
What’s Next?
You don’t have to wait for the next failure. Start protecting your process now.
