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How to Create the Best Custom Surgical Tray for Your Practice 

CPTBlog-BANNER-creating-custom

Considerations

A surgeon’s tray is one of his or her most important tools in operation. Several questions should be asked before you decide on even the proper family of trays you’ll need. This is why custom trays are so popular today. Before customizing yours, ask yourself:

  • What kind of operations is this tray for?
  • What kind of tools are required?
  • Does the tray need to be suspended?
  • What kind of budget are you working with?
  • What sterilization measures are necessary/available?
  • Utility–how comfortable/awkward is the tray? It can’t delay necessary action.

Tray Characteristics

Generally, surgeons are looking for trays that are:

  • Easy to Sterilize: Sometimes surgery must happen extremely fast, and a tray that’s hard to sterilize can lose a life. Ideally, sterilization procedure should be very fast, and very straightforward. Custom trays are more likely to be designed this way than some non-custom options.
  • Sturdy: Custom trays should be strong enough to handle the load of necessary equipment for the operations they’ll be supporting. Whether that load be suspended or lifted up, the tray should accommodate without difficulty.
  • Effective at Consolidating Time: A tray’s weight, dimensions, and features will all help save time. Time is life in medical operations; and without life, there is no money.
  • Well-Manufactured: Whether the tray is a disposable one, or meant for continual reuse, it should be built to withstand not just procedural necessity, but the unpredictable.
  • Disposable Options: Procedure packs and customizable disposable trays have, for quite a while now, been used in surgical proceedings. What these amount to is packages of necessary operation equipment that can be bought in bulk already-sterilized and ready for operation. Both trays and equipment can be acquired this way, saving time and energy in operational preparation and performance. Again, when time is life, expense is tertiary. Though disposable customizable options may be more costly, they will definitely be more effective at helping speedy operations that may save lives.

Dependability of Manufacture and Shipping

When ordering custom trays, be sure to get them from a source which has a solid history of steady, accurate delivery. Medicine is an endlessly necessary function of modern society. As such, the needs of medical facilities increase as the population does. Though shipping, purchasing, and reprisal occur in a cyclic way, there are perpetual demands for equipment; especially of the disposable sterilized variety. As a result, it is not uncommon for custom procedural packs or custom trays to become lost, or mixed up, during shipment. Sometimes custom trays are purchased in bulk, and individually wrapped in a sterilized way containing all necessary operational equipment. But when the first custom trays are opened from the shipment, it is found the items inside do not correspond to the items requisitioned. Such mix-ups are going to be more common among manufacturers who are new to the market, or are perhaps overloaded with clientele. To avoid this, you should order custom trays in dual shipments and keep firm records of contents when they arrive. The better organizations will certainly ship the right items without additional expense to the surgical practice in question. Such errors should not happen, but they are subject to human imperfection, and so they cannot be curtailed; only recognized and planned for.

Reusable Custom Trays

While it is possible to find custom trays that are reusable, and so won’t ever ship with the wrong contents, sterilization can be difficult on-the-fly, and unless some unique system be devised by your practice, will not be something that can be accomplished as quickly as simply opening a pre-sterilized pack. Still, some delicate procedures may require direct reusable customization.

Different Chemical Sterilizations

Surgical equipments

Sterilization is as old as medicine. For ages, man has either consciously or remotely know the relationship between dirt, microbes, infections and decay. The battle against decay and infections has pushed doctors and scientists into developing different sterilization methods geared towards eradicating and keeping off any form of microbes on a surface, custom trays or a substance. The most popular procedure include heat treatment and chemical sterilization.

When is Chemical Sterilization Most Appropriate?

Chemical sterilization comes in when the device in use, or the target substance, is sensitive to heat. This could be rubber or plastic custom trays. Most of the chemical sterilizers are highly reactive low temperature gases or liquid that will either be in direct contact with the target substance or interact with it through a semi-porous membrane or custom strays.

A variety of chemical sterilization procedures exist to cater for sterilant-item compatibility. Choosing the right sterilization chemical will help you avoid contamination or chemical damage to the item you wish to sterilize.

The most common procedures that will work with custom trays in the lab include

  • Ethylene oxide
  • Aldehydes
  • Alcohols
  • Phenols
  • Halogens

Ethylene Oxide Chemical Sterilization

Ethylene oxide is a highly toxic, flammable, reactive gas that is appropriate for custom trays sterilization at relatively low temperatures. It’s high penetration rates gives it the power to seep through different custom trays, for instance thin plastic membranes, making it appropriate for thorough equipment sterilization.

The fact that the gas doesn’t work so well on dried microorganisms limits its use as a general purpose sterilizer. A relative humidity of 40 to 90 percent is necessary to improve efficiency and you must let the sterilized equipment lie for a while to get rid of all the ethylene oxide from the custom trays.

Aldehydes

The most popular aldehyde that dominates the custom trays chemical sterilization arena is formaldehyde. This water-soluble gas is easy to deploy using special gas apparatus. It is effective on a wide range of viruses, fungi and bacteria. It will disinfect custom trays and other equipment when dissolved in water while a controlled gaseous discharge can disinfect the air inside rooms.

Direct contact with the skin could result into inflammation or eczemas.

Alcohol Sterilization

Alcohols are a perfect protection against bacteria and fungi. Even though they cannot kill bacteria spores, their rapid action and relatively safe handling makes them the one-touch sterilant of choice during surgical, laboratory or general skin and hand disinfection. The most popular alcohols used in this case are

  • 80 percent ethanol
  • 60 percent propanol
  • 70 percent isopropanol

Phenols

Phenol, or simply carbolic acid, is a popular protein denaturing sterilization chemical that could work in specific substance sterilization. They are relatively weak and will rarely perform well against spores and viruses. Their moderate effect on organic materials makes them suitable for disinfecting products rather than applying on used equipment and apparatus.

Halogens

Last on the list of popular chemical sterilization options is chlorine and iodine. These halogens are a popular general microbicidals that are strong enough to kill spores and are rarely use to sterilize custom trays. Chlorine will sterilize and disinfect many things, from water to equipment and surfaces. The less strong iodine often mixes with potassium iodide with alcohol to create tincture of iodine that is used to disinfect skin and small wounds.

Choosing the right chemical disinfectant for the right job will not only ensure total sterilization but also keep the integrity of your equipment and their intended use. The best way to staying on top of this is by understanding how each sterilant works, its strengths and weaknesses from the word go.

What Are The Methods Of Sterilization?

Surgical equipments

Sterilization is a process of eradicating live microorganisms from substances. It is done to preserve things for a long time and kill germs. If something is not sterilized, it may cause infection to those who use it. Therefore, it should not be taken for granted. There are several methods of sterilization, including:

Heat sterilization


This is the most common type of sterilization because the heat used kills all microbes. The extent of sterilization is affected by the duration of heating and heat temperature. As the temperature goes up, the duration of heating goes up. The heat method of sterilization can be further divided into two:

Moist heat methods

Here, heat is applied through boiling and includes methods like pasteurization, using steam, and boiling. Boiling is done for metal devices such as surgical scissors, custom trays, and needles. The substances are boiled to kill any microbes. Pasteurization, on the other hand, is a method for heating milk to 60 or 72 degrees thrice or four times.

When using steam, the substances being sterilized are subjected to steam in autoclave steam heating equipment. The process uses temperatures of up to 115 degrees for an hour. It is the most common method for sterilizing drugs because it can kill the bacterial spores, which are inert bacterial forms.

Dry heat methods

Substances are subjected to flaming, incineration, hot air ovens, or radiation sterilization. In flaming, metallic devices such as needles or scalpels are placed over a flame for several minutes. The flame will kill all microbes directly. Incineration is used especially for inoculating the loops utilized in microbe cultures. The loop’s metallic end is burnt red hot on a flame, killing all microbes.

The radiation method involves the exposure of packed materials to radiation. There are two types of radiation: non-ionic and ionizing radiation sterilization. The former is safe to the person doing the procedure while the latter requires the operator to wear protective gear. The hot air method is ideal for dry materials such as glassware and powder. They are placed inside the racks of a hot air oven until sterilized.

Chemical sterilization


In this method, the items are subjected to sterilization through toxic gasses. When sterilizing heat sensitive liquids, you should use bacterial filters. Three types of filters are used in this type of check this sterilization:

  • Seitz filters – they are made from materials such as asbestos and are pad-like and thicker than a membrane filter. Seitz filters do not rupture during the process of filtration. However, the solution can end up being absorbed by the filter. An alternative to Seitz filters are sintered glass filters, which are made of glass and hence cannot absorb liquids. However, they are fragile and breakable.
  • Membrane filters – these thin filters are made of cellulose and can be used for online sterilization during injections. The membrane is placed between the needle and syringe. However, this type of filter can rupture easily causing improper sterilization.
  • Candle filters – they are made from clay such as diatomous mud, which has small pores made by algae. The filters have many lengthy pores that trap the microbes as they travel through the candle.

The type of filter that you choose depends on the substance that you want to sterilize. When using gas to sterilize, cost factors as well as chances of explosion should be considered. The gasses used are usually very toxic and should be used with caution. If you want to sterilize surgical instruments, the most effective methods are autoclave, boiling, and incineration.

What’s Included in Procedure Packs

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Image is from www.bbc.com

What You Need

A procedure pack’s contents may best be summarized with the term “custom tray”. A custom tray will generally be customized by the surgeon, orthodontist, or dentist who is using it. If, for example, you were working on the spine, common inclusions in a given spine pack are:

  • A Benzoin Ampule
  • 5 by 7.5 Foot Table Cover, Super HD
  • 3/4 Sheet Drape of 53 and 77 Inches
  • Needle, 22GX1.5″
  • Spinal Needal, 18GX3.5″
  • Needle Counter, 40-Count
  • Telfa Pad, Non-Adhesive (8″x3″)
  • Petri Dish
  • Pitcher, 1,200 CC
  • Lap Sponges, X-Ray Detectable, 18X18 Inches (10)
  • Neuro Sponges, X-Ray Detectable, 5X5 Inches (10)
  • Neuro Sponges, X-Ray Detectable, 3X5 Inches (10)
  • Neuro Sponges, X-Ray Detectable, 1X1 Inches (10)
  • Blue OR Towels (15)

Custom Trays To Fit Specific Needs

Whatever kind of custom tray you choose, you have the ability to add whatever necessary items you would like. A procedure pack can be fitted with the regular needs of a specific procedure as outlined in textbooks from varying sources. Additionally, you can make your own custom tray that includes more items. You may have some patients who require additional neuro sponges, and the forty of varying sizes included in regular packs may not cut it. Perhaps you prefer to have additional syringes in your custom tray, because you’ve had several close calls where such were needed in a hurry. Perhaps there are even items in this spine pack that you feel have been left out, and you’d prefer to add them. With a custom tray, you have that ability.

Professional Custom Tray Provision

While it is possible for you to create your own custom tray at your practice with a minimum of difficulty, the problem is you’ll have to source items like those listed on your own time. Many medical practices have a supply division that manages such resources. Oftentimes in these scenarios, supplies are bought and paid for by clinics through a variety of vendors at different prices. If surgical procedural packs are made on-site, it may require the allocation of medical workers’ time. As a matter of fact, you’ll likely need several employees just to ensure each custom tray has the right equipment and is properly sterilized.

Or, you can cut out all that unnecessary infrastructure and instead order procedure packs that fit your clinic’s regular patients. While you may get outliers, then you can use local staff to put together surgical equipment for such a statistically minimal scenario. For everything else, it makes plenty of sense to order custom trays fitted to your needs in advance. You should have several custom tray families; one for backup, and one for regular use. A third group is not a bad idea either, should difficulties manifest.

Final Considerations

With the ability to consolidate local resources and ensure each custom tray you order fits your specifications, it’s easy to see the appeal of this medical innovation. Having a custom tray or procedure pack handy in an emergency could very well save a person’s life. While it makes sense to maintain sterilization means on any facility, it also makes sense to plan for situations where there’s no time to book an appointment. Life doesn’t always stick to a schedule book.

Between the convenience of off-site resource consolidation and presentation, the savings that are rendered to your practice’s infrastructural and purchasing divisions, and the benefit of having immediate access to necessary surgical supplies in a possible emergency, there are a lot of things which recommend custom trays. More than being available, their customizable quality ensures you get what you need, when you need it, how you like it.

How to create a custom surgical tray

CPTBlog-BANNER-creating-custom

Considerations

A surgeon’s tray is one of his or her most important tools in operation. Several questions should be asked before you decide on even the proper family of trays you’ll need. This is why custom trays are so popular today. Before customizing yours, ask yourself:

  • What kind of operations is this tray for?
  • What kind of tools are required?
  • Does the tray need to be suspended?
  • What kind of budget are you working with?
  • What sterilization measures are necessary/available?
  • Utility–how comfortable/awkward is the tray? It can’t delay necessary action.

Tray Characteristics

Generally, surgeons are looking for trays that are:

  • Easy to Sterilize: Sometimes surgery must happen extremely fast, and a tray that’s hard to sterilize can lose a life. Ideally, sterilization procedure should be very fast, and very straightforward. Custom trays are more likely to be designed this way than some non-custom options.
  • Sturdy: Custom trays should be strong enough to handle the load of necessary equipment for the operations they’ll be supporting. Whether that load be suspended or lifted up, the tray should accommodate without difficulty.
  • Effective at Consolidating Time: A tray’s weight, dimensions, and features will all help save time. Time is life in medical operations; and without life, there is no money.
  • Well-Manufactured: Whether the tray is a disposable one, or meant for continual reuse, it should be built to withstand not just procedural necessity, but the unpredictable.
  • Disposable Options: Procedure packs and customizable disposable trays have, for quite a while now, been used in surgical proceedings. What these amount to is packages of necessary operation equipment that can be bought in bulk already-sterilized and ready for operation. Both trays and equipment can be acquired this way, saving time and energy in operational preparation and performance. Again, when time is life, expense is tertiary. Though disposable customizable options may be more costly, they will definitely be more effective at helping speedy operations that may save lives.

Dependability of Manufacture and Shipping

When ordering custom trays, be sure to get them from a source which has a solid history of steady, accurate delivery. Medicine is an endlessly necessary function of modern society. As such, the needs of medical facilities increase as the population does. Though shipping, purchasing, and reprisal occur in a cyclic way, there are perpetual demands for equipment; especially of the disposable sterilized variety. As a result, it is not uncommon for custom procedural packs or custom trays to become lost, or mixed up, during shipment. Sometimes custom trays are purchased in bulk, and individually wrapped in a sterilized way containing all necessary operational equipment. But when the first custom trays are opened from the shipment, it is found the items inside do not correspond to the items requisitioned. Such mix-ups are going to be more common among manufacturers who are new to the market, or are perhaps overloaded with clientele. To avoid this, you should order custom trays in dual shipments and keep firm records of contents when they arrive. The better organizations will certainly ship the right items without additional expense to the surgical practice in question. Such errors should not happen, but they are subject to human imperfection, and so they cannot be curtailed; only recognized and planned for.

Reusable Custom Trays

While it is possible to find custom trays that are reusable, and so won’t ever ship with the wrong contents, sterilization can be difficult on-the-fly, and unless some unique system be devised by your practice, will not be something that can be accomplished as quickly as simply opening a pre-sterilized pack. Still, some delicate procedures may require direct reusable customization.