Webinar Recap -Alternative Sterilization for Healthcare Packaging: Chlorine Dioxide Deep Dive

With growing regulatory demands, supply chain constraints, and sustainability concerns challenging established sterilization methods, the industry is exploring other options. Which is why in 2026 Oliver will host a webinar series focused on educating you on the newer sterilization methods in industry and their impact on packaging. In the first webinar in this series, ClorDiSys joined us to talk about one alternate modality: chlorine dioxide (ClO2).

The session provided packaging professionals with an overview of chlorine dioxide sterilization—how it works, where it fits alongside established methods like ethylene oxide (EO), and what it means for packaging design and material selection.

Setting the Stage

The webinar opened by grounding the discussion in today’s sterilization landscape. In the medical packaging industry, EO and gamma radiation remain dominant. Both are used to sterilize billions of single use medical devices each year, but they are increasingly impacted by regulatory, environmental, and logistical challenges. Rather than replacing EO or gamma, the industry is pursuing diversification by offering innovative alternatives such as ClO2.

Understanding Chlorine Dioxide Sterilization

Emily Lorcheim, Vice President of Sterilization Technologies at ClorDiSys, provided a detailed overview of the science behind chlorine dioxide and its use in sterilization. She challenged assumptions and guided listeners through various considerations when exploring chlorine dioxide sterilization.

When sterilizing using the chlorine dioxide method, it's important to pay attention to four key factors: concentration, dosage, relative humidity, and pressure. Concentration affects how long the process takes, but not its effectiveness—the higher the concentration the shorter the cycle. Dosage is determined by multiplying concentration and time; higher packaging volume may require increased dosage to reach the validated requirements. For relative humidity, maintaining an Rh between 65% and 75% assists in gas penetration. Additionally, longer conditioning times might be needed with more extensive packaging. Pressure can vary from ambient up to 5 kPa, but should increase in pressure with the complexity of the device to increase gas penetration.

Comparing Chlorine Dioxide and Ethylene Oxide

A key portion of the webinar also focused on a side-by-side comparison of chlorine dioxide and EO. While both are highly effective gaseous sterilants with broad material compatibility, chlorine dioxide can offer advantages in certain applications:

• Non-carcinogenic and non-explosive

• Significantly shorter cycle times 

• Zero emissions

• Non-detectable, safe residuals 

Implications for Packaging Design and Materials

Jeremy Elwell, Technical Services Manager at Oliver Healthcare Packaging, added to the conversation by discussing packaging considerations when sterilizing with ClO2. Drawing on collaborative testing between Oliver and ClorDiSys, Jeremy shared that the data demonstrated strong compatibility between chlorine dioxide and common flexible sterile barrier materials, such as:

• Coated and uncoated DuPont Tyvek®

• Medical-grade papers and cellulose-based materials

• Polyester- and nylon-based pouching films

Testing evaluated seal strength, puncture resistance, tensile properties, and long-term performance through accelerated aging. Across all configurations, results showed no adverse functional effects over time when compared to non-sterilized controls.

Jeremy also addressed potential risks such as seal creep and film delamination, which are issues that can occur with any gas sterilization method. He emphasized that these risks are manageable through proper material selection and packaging design, reinforcing the importance of early collaboration between device, packaging, and sterilization partners.

Key Takeaways

The webinar concluded with several clear messages for packaging and device professionals:

• Chlorine dioxide is a safe and effective sterilization option. 

• Chlorine dioxide sterilization is compatible with a broad range of devices and packaging materials.

• Thoughtful packaging design and material selection are still critical, along with an understanding of the cycle process and parameters for a successful sterile barrier system. 

• Emerging sterilization methods are on the rise and chlorine dioxide is best viewed as part of the growing sterilization options.

You can find the webinar in full below.