On This Page On This Page PURCHASE WITH CONFIDENCE Discover the 17 questions you need to ask before buying your next autoclave. Get the Guide Do You Need a Large Capacity Autoclave? [Or Do You Just Think You Do?] Written by: Arthur Trapotsis MS Biochemical Engineering, MBA, Consultant “Large” may be a relative term, but in the world of steam sterilization, there’s a generally accepted threshold. Any autoclave large enough to walk into or that requires a pit to be excavated beneath the facility floor is considered a large capacity or bulk autoclave. These units are typically upward of 1,000L (36 cubic feet) and are reserved for high-volume applications such as vivarium cage sterilization and biohazardous waste processing. In this article, we’ll talk about the different types of large capacity autoclaves, as well as some clever workarounds for facilities that require the processing capacity of (but may not have the available space for) a bulk autoclave. Key Takeaways: A large capacity autoclave is generally defined as any unit larger than 1,000L (36 cubic feet). Before investing in a bulk autoclave, it’s worth exploring whether a custom-configured, medium-sized unit can meet your capacity requirements. If you do need a large capacity autoclave but have limited floor space, recessing the unit into a wall and configuring it for single-side service access can reduce your footprint. Multiple medium-sized autoclaves are often a more flexible and cost-effective alternative to a single large unit, especially for facilities that need redundancy or expect their sterilization needs to evolve over time. Most Common Types of Large Autoclaves Though there are a wide variety of large capacity autoclaves on the market, these models are the most common types used in life science laboratory and healthcare settings: High-capacity walk-in autoclaves derive their name from their chamber size — sometimes six feet or more in total height — which allows personnel to physically enter the chamber during loading and unloading.To make loading as easy as possible, these units are typically installed in an excavated pit so that the bottom of the chamber sits level with the floor, enabling operators to wheel loaded carts directly in without a transfer carriage. This configuration is purpose-built for high-volume throughput, which is a major selling point. The tradeoff is a lack of built-in organizational features, such as internal shelving, meaning operators must rely on cart and rack systems. High-capacity freestanding autoclaves split the difference between a walk-in unit and a standard laboratory autoclave. They offer substantially more chamber volume than a bench-top or floor-standing unit without the need for pit installation. Freestanding units can also support customization, such as internal shelving and vertical sliding doors, making them well-suited for facilities with specialized load types. Retorts are a type of large autoclave used primarily in food and beverage processing. Unlike walk-in or freestanding units, retorts feature an elongated chamber and are designed to heat-treat packaged foods and beverages to extend shelf life. Most retorts are equipped with a conveyance system, and goods are either loaded into the chamber on carts or automatically as part of a larger assembly line. How to Determine Whether You Need a Large Capacity Autoclave If you’re considering a large capacity autoclave, you should first determine how many loads you need to process per day, and what those loads consist of. Cage sterilization in a vivarium, for example, has very different throughput requirements than biohazardous waste processing in a biosafety research facility, even if the two programs seem similar on paper. Next, ask yourself whether you actually need a large unit to meet that throughput, or if a medium-sized autoclave — or multiple medium-sized autoclaves — could do the job just as well. Even a relatively minor increase in chamber size can dramatically improve throughput. For example, moving from a 24” x 24” x 48” chamber to a 26” x 26” x 49” chamber could allow for an additional row of goods on each shelf. That’s a substantial increase in overall yield, and at a much lower cost than stepping up to a bulk unit. If you’re unsure whether your current or projected load volume requires a large capacity autoclave, Consolidated’s engineering team can run the numbers with you. Finally, if you’ve determined that a bulk unit is the right call, give serious thought to the installation path before you order. Some large capacity autoclaves can be as long as 120”, and narrow hallways, small doorways, low ceilings, and undersized freight elevators can all derail installations that look straightforward on a floor plan. For best results, walk the route from loading dock to the final installation location before finalizing a spec. Infrastructure Considerations for Large Capacity Autoclaves The utility and structural requirements of large capacity autoclaves are vastly different from those of standard laboratory units, and facilities that discover these gaps after placing an order often face delays, unexpected costs, and significant construction work. To avoid the most common installation surprises, consider the following: Steam Supply: Bulk units typically require house steam at a minimum of 50 PSI. If your facility’s house steam is insufficient or unavailable, you’ll need an electric steam generator — and for chamber sizes of 24” x 36” x 60” or larger, that means a remote-mounted boiler, which cannot fit beneath the autoclave and must be installed in an adjacent room or utility space. Remote boilers require their own electrical connections, water supply lines, and physical footprint, all of which you’ll need to factor into your facility layout from the start. Electrical: Large capacity autoclaves generally require three-phase power, and the specific voltage and amperage draw varies by unit. Depending on the unit, you may need to invest in a buck-boost transformer to bring the standard voltage supply up to the required voltage. Confirm your facility’s electrical panel capacity and the distance from the panel to the installation site before specifying a unit; a long run can require larger-gauge wiring and add to installation costs. Drainage: Large capacity autoclaves generate significant volumes of hot effluent during each cycle. Many municipalities and building codes prohibit effluent above 140°F (60°C) from entering the floor drain directly, which means your autoclave will need a cooling mechanism — either a mixing valve that blends in cold water or a heat exchanger — as well as an appropriately sized floor drain. Check the unit’s effluent flow rate against your drain’s capacity prior to purchase. Floor Loading Capacity: A bulk unit can weigh 1,000 kg or more before the load is even added. In a pit installation, that weight is concentrated over a relatively small footprint. While this might not be an issue in new buildings, it’s worth having a structural engineer verify that the floor slab can support the load before construction (in the case of a walk-in unit) or installation. What to Do If You Don’t Have Room for a Bulk Autoclave If you need a large capacity autoclave but floor space is tight, there are a few ways to reduce the unit’s footprint without compromising its function. The most effective is to recess the unit into a wall, with the chamber size facing the production or processing area and the service components — plumbing, electrical, steam connections — in a utility space on the other side. This is a standard installation approach for large autoclaves in production facilities and allows full service access without the autoclave occupying production floor space. Wherever possible, configure large autoclaves so that service is only required on one side of the unit. A single-side service configuration means you can push the autoclave against a wall or into a corner on its non-service side. When planning the layout, also account for door swing direction, control panel placement, and cart and carriage positioning. These variables are often adjustable at the time of order and can mean the difference between an autoclave that fits a tight space cleanly and one that creates a workflow problem every time someone needs to load it. Facilities looking to increase their load capacity without having to significantly rearchitect should consider multiple medium-sized freestanding autoclaves, instead. Depending on the manufacturer, you can custom configure these units with loading carts and carriages or internal shelving, vertical sliding doors, tall chambers for glassware and bioreactors, and other features that can approximate the throughput of a bulk autoclave with more flexibility and a lower per-unit cost. There’s also the redundancy argument: Two medium units means that a single autoclave going down for service won’t halt operations entirely. Some specific configurations to consider: A single stationary wire shelf to prevent drain blockages works well for facilities that primarily sterilize unstructured loads such as biohazardous waste bags. Integral shelving with a loading cart and carriage maximizes usable chamber volume and speeds up loading for facilities that run a high number of packaged or racked loads per day. A taller-than-wide chamber can accommodate tall glassware, bioreactors, and other instrumentation that doesn’t fit comfortably in a standard aspect ratio. A vertical sliding door with foot pedal operation is worth considering for facilities where operators regularly push fully loaded carts into the chamber, or where cross-contamination from handling the door is a concern. For additional guidance on large capacity autoclaves, installation planning, or custom configurations, contact the team at Consolidated Sterilizer Systems. Whether you need a true bulk unit or a custom-configured alternative that gets you the same throughput in a smaller footprint, our engineering team can help you find the right solution. Frequently Asked Questions Q: What is a large capacity autoclave? A: A large capacity autoclave is generally defined as any autoclave larger than 1,000L (36 cubic feet) that requires a pit or dedicated room to install. Walk-in units, high-capacity freestanding units, and retorts all fall into this category, though the exact threshold varies by manufacturer. Q: What types of large capacity autoclaves are available? A: There are many types of large capacity autoclaves available, though the three most common found in life science and healthcare settings are high-capacity walk-in autoclaves, high-capacity freestanding autoclaves, and retorts. Walk-in units require a pit installation and are purpose-built for maximum throughput. High-capacity freestanding units tend to offer more flexibility and customization options. Retorts are specialized for food and beverage processing. Q: What should I do if I need the processing capabilities of a large capacity autoclave but don’t have space for one? A: If you need the processing capabilities of a large capacity autoclave but don’t have the space for one, your best options are to either recess the unit into a wall to keep service components out of the usable floor area, or to configure it for service-side access so that you can place it against a wall or in the corner. As an alternative, you might want to consider one or more medium-sized units. In many cases, these autoclaves can be configured to provide similar throughput to a bulk unit, but with more flexibility and a lower cost per unit. Should you choose to purchase multiple medium-sized units, you’ll also benefit from built-in redundancy should one unit go down for service. Q: How do I know whether I actually need a large capacity autoclave? A: To know whether you need a large capacity autoclave, start by determining how many cycles you intend to run per day, and what your typical load type is. From there, Consolidated’s team of engineers can work with you to determine if a custom-configured medium-sized unit could meet your throughput requirements, or if you genuinely need a bulk unit. Ready to Make Your Next Autoclave Purchase? Read This, First An autoclave — especially a large capacity one — is a major investment, one that requires careful consideration. We’ve created this buyers’ guide to help you ask the right questions and make an informed decision. Get the Guide Tweet Like Share
Do You Need a Large Capacity Autoclave? [Or Do You Just Think You Do?] Written by: Arthur Trapotsis MS Biochemical Engineering, MBA, Consultant “Large” may be a relative term, but in the world of steam sterilization, there’s a generally accepted threshold. Any autoclave large enough to walk into or that requires a pit to be excavated beneath the facility floor is considered a large capacity or bulk autoclave. These units are typically upward of 1,000L (36 cubic feet) and are reserved for high-volume applications such as vivarium cage sterilization and biohazardous waste processing. In this article, we’ll talk about the different types of large capacity autoclaves, as well as some clever workarounds for facilities that require the processing capacity of (but may not have the available space for) a bulk autoclave. Key Takeaways: A large capacity autoclave is generally defined as any unit larger than 1,000L (36 cubic feet). Before investing in a bulk autoclave, it’s worth exploring whether a custom-configured, medium-sized unit can meet your capacity requirements. If you do need a large capacity autoclave but have limited floor space, recessing the unit into a wall and configuring it for single-side service access can reduce your footprint. Multiple medium-sized autoclaves are often a more flexible and cost-effective alternative to a single large unit, especially for facilities that need redundancy or expect their sterilization needs to evolve over time. Most Common Types of Large Autoclaves Though there are a wide variety of large capacity autoclaves on the market, these models are the most common types used in life science laboratory and healthcare settings: High-capacity walk-in autoclaves derive their name from their chamber size — sometimes six feet or more in total height — which allows personnel to physically enter the chamber during loading and unloading.To make loading as easy as possible, these units are typically installed in an excavated pit so that the bottom of the chamber sits level with the floor, enabling operators to wheel loaded carts directly in without a transfer carriage. This configuration is purpose-built for high-volume throughput, which is a major selling point. The tradeoff is a lack of built-in organizational features, such as internal shelving, meaning operators must rely on cart and rack systems. High-capacity freestanding autoclaves split the difference between a walk-in unit and a standard laboratory autoclave. They offer substantially more chamber volume than a bench-top or floor-standing unit without the need for pit installation. Freestanding units can also support customization, such as internal shelving and vertical sliding doors, making them well-suited for facilities with specialized load types. Retorts are a type of large autoclave used primarily in food and beverage processing. Unlike walk-in or freestanding units, retorts feature an elongated chamber and are designed to heat-treat packaged foods and beverages to extend shelf life. Most retorts are equipped with a conveyance system, and goods are either loaded into the chamber on carts or automatically as part of a larger assembly line. How to Determine Whether You Need a Large Capacity Autoclave If you’re considering a large capacity autoclave, you should first determine how many loads you need to process per day, and what those loads consist of. Cage sterilization in a vivarium, for example, has very different throughput requirements than biohazardous waste processing in a biosafety research facility, even if the two programs seem similar on paper. Next, ask yourself whether you actually need a large unit to meet that throughput, or if a medium-sized autoclave — or multiple medium-sized autoclaves — could do the job just as well. Even a relatively minor increase in chamber size can dramatically improve throughput. For example, moving from a 24” x 24” x 48” chamber to a 26” x 26” x 49” chamber could allow for an additional row of goods on each shelf. That’s a substantial increase in overall yield, and at a much lower cost than stepping up to a bulk unit. If you’re unsure whether your current or projected load volume requires a large capacity autoclave, Consolidated’s engineering team can run the numbers with you. Finally, if you’ve determined that a bulk unit is the right call, give serious thought to the installation path before you order. Some large capacity autoclaves can be as long as 120”, and narrow hallways, small doorways, low ceilings, and undersized freight elevators can all derail installations that look straightforward on a floor plan. For best results, walk the route from loading dock to the final installation location before finalizing a spec. Infrastructure Considerations for Large Capacity Autoclaves The utility and structural requirements of large capacity autoclaves are vastly different from those of standard laboratory units, and facilities that discover these gaps after placing an order often face delays, unexpected costs, and significant construction work. To avoid the most common installation surprises, consider the following: Steam Supply: Bulk units typically require house steam at a minimum of 50 PSI. If your facility’s house steam is insufficient or unavailable, you’ll need an electric steam generator — and for chamber sizes of 24” x 36” x 60” or larger, that means a remote-mounted boiler, which cannot fit beneath the autoclave and must be installed in an adjacent room or utility space. Remote boilers require their own electrical connections, water supply lines, and physical footprint, all of which you’ll need to factor into your facility layout from the start. Electrical: Large capacity autoclaves generally require three-phase power, and the specific voltage and amperage draw varies by unit. Depending on the unit, you may need to invest in a buck-boost transformer to bring the standard voltage supply up to the required voltage. Confirm your facility’s electrical panel capacity and the distance from the panel to the installation site before specifying a unit; a long run can require larger-gauge wiring and add to installation costs. Drainage: Large capacity autoclaves generate significant volumes of hot effluent during each cycle. Many municipalities and building codes prohibit effluent above 140°F (60°C) from entering the floor drain directly, which means your autoclave will need a cooling mechanism — either a mixing valve that blends in cold water or a heat exchanger — as well as an appropriately sized floor drain. Check the unit’s effluent flow rate against your drain’s capacity prior to purchase. Floor Loading Capacity: A bulk unit can weigh 1,000 kg or more before the load is even added. In a pit installation, that weight is concentrated over a relatively small footprint. While this might not be an issue in new buildings, it’s worth having a structural engineer verify that the floor slab can support the load before construction (in the case of a walk-in unit) or installation. What to Do If You Don’t Have Room for a Bulk Autoclave If you need a large capacity autoclave but floor space is tight, there are a few ways to reduce the unit’s footprint without compromising its function. The most effective is to recess the unit into a wall, with the chamber size facing the production or processing area and the service components — plumbing, electrical, steam connections — in a utility space on the other side. This is a standard installation approach for large autoclaves in production facilities and allows full service access without the autoclave occupying production floor space. Wherever possible, configure large autoclaves so that service is only required on one side of the unit. A single-side service configuration means you can push the autoclave against a wall or into a corner on its non-service side. When planning the layout, also account for door swing direction, control panel placement, and cart and carriage positioning. These variables are often adjustable at the time of order and can mean the difference between an autoclave that fits a tight space cleanly and one that creates a workflow problem every time someone needs to load it. Facilities looking to increase their load capacity without having to significantly rearchitect should consider multiple medium-sized freestanding autoclaves, instead. Depending on the manufacturer, you can custom configure these units with loading carts and carriages or internal shelving, vertical sliding doors, tall chambers for glassware and bioreactors, and other features that can approximate the throughput of a bulk autoclave with more flexibility and a lower per-unit cost. There’s also the redundancy argument: Two medium units means that a single autoclave going down for service won’t halt operations entirely. Some specific configurations to consider: A single stationary wire shelf to prevent drain blockages works well for facilities that primarily sterilize unstructured loads such as biohazardous waste bags. Integral shelving with a loading cart and carriage maximizes usable chamber volume and speeds up loading for facilities that run a high number of packaged or racked loads per day. A taller-than-wide chamber can accommodate tall glassware, bioreactors, and other instrumentation that doesn’t fit comfortably in a standard aspect ratio. A vertical sliding door with foot pedal operation is worth considering for facilities where operators regularly push fully loaded carts into the chamber, or where cross-contamination from handling the door is a concern. For additional guidance on large capacity autoclaves, installation planning, or custom configurations, contact the team at Consolidated Sterilizer Systems. Whether you need a true bulk unit or a custom-configured alternative that gets you the same throughput in a smaller footprint, our engineering team can help you find the right solution. Frequently Asked Questions Q: What is a large capacity autoclave? A: A large capacity autoclave is generally defined as any autoclave larger than 1,000L (36 cubic feet) that requires a pit or dedicated room to install. Walk-in units, high-capacity freestanding units, and retorts all fall into this category, though the exact threshold varies by manufacturer. Q: What types of large capacity autoclaves are available? A: There are many types of large capacity autoclaves available, though the three most common found in life science and healthcare settings are high-capacity walk-in autoclaves, high-capacity freestanding autoclaves, and retorts. Walk-in units require a pit installation and are purpose-built for maximum throughput. High-capacity freestanding units tend to offer more flexibility and customization options. Retorts are specialized for food and beverage processing. Q: What should I do if I need the processing capabilities of a large capacity autoclave but don’t have space for one? A: If you need the processing capabilities of a large capacity autoclave but don’t have the space for one, your best options are to either recess the unit into a wall to keep service components out of the usable floor area, or to configure it for service-side access so that you can place it against a wall or in the corner. As an alternative, you might want to consider one or more medium-sized units. In many cases, these autoclaves can be configured to provide similar throughput to a bulk unit, but with more flexibility and a lower cost per unit. Should you choose to purchase multiple medium-sized units, you’ll also benefit from built-in redundancy should one unit go down for service. Q: How do I know whether I actually need a large capacity autoclave? A: To know whether you need a large capacity autoclave, start by determining how many cycles you intend to run per day, and what your typical load type is. From there, Consolidated’s team of engineers can work with you to determine if a custom-configured medium-sized unit could meet your throughput requirements, or if you genuinely need a bulk unit. Ready to Make Your Next Autoclave Purchase? Read This, First An autoclave — especially a large capacity one — is a major investment, one that requires careful consideration. We’ve created this buyers’ guide to help you ask the right questions and make an informed decision. Get the Guide Tweet Like Share
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