Also called: Autoclave loading, Load configuration, Pouches and trays
How to Load an Autoclave So Every Item Sterilises
Steam has to reach every surface and air has to get out. How you arrange the load decides whether that happens — and whether packs come out dry.
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Before anything goes in
- Every item has been cleaned, rinsed, dried and inspected — water on instruments becomes a wet pack.
- Pouches are sealed along their full width, labelled outside the seal and not overfilled.
- Hinged instruments are opened or unlocked, and anything designed to come apart is taken apart.
- Hollow or wrapped items only go into a Class B (or suitably validated Class S) cycle.
- The day’s air-removal test has passed on vacuum units.
Read next Cleaning before sterilisationWhich class handles which load
Loading rules that matter most
Pouches on edge
Stand pouches on edge in a rack where possible, paper side facing plastic side, with a little space between them. If they must lie flat, use a single layer without overlap and follow the steriliser and pouch makers’ instructions on which side faces up.
Do not overload
Each model has a stated maximum load per tray and per cycle. Overloading slows air removal, leaves cold spots and is the most common cause of wet packs.
Keep clear of the walls
Nothing should touch the chamber walls or door. Contact with hot walls can scorch paper, and blocked airflow traps air.
Tilt anything that holds water
Place bowls, cups, kidney dishes and containers on their side or upside down, so air can drain out and condensate cannot pool.
Heavy metal low, textiles high
In mixed loads, put heavy instrument sets on the lower trays and textiles or porous packs above them, so condensate from metal does not drip onto fabric.
Hollow items and indicators
- Lumens must be clean, dry and open at both ends — never cap or plug them for sterilising.
- Dental handpieces and other complex devices go in as their makers’ instructions say, often in their own pouch.
- Place an internal chemical indicator (integrator) inside the hardest-to-reach pack, such as the centre of the densest one.
- Use the cycle suited to the most demanding item in a mixed load, not the fastest one available.
Read next Pouches, tape and indicators
Common loading mistakes
| Mistake | What happens |
|---|---|
| Pouches stacked flat and overlapping | Air pockets between layers; packs stay wet or are not sterilised |
| Containers upright | Air and condensate trapped inside the container |
| Textiles below metal sets | Condensate drips onto fabric and leaves wet packs |
| Too many items on one tray | Slow heat-up, cold spots and failed drying |
| Instruments locked closed | Steam cannot reach the surfaces inside the joint |
| Wrapped items in a Class N cycle | No proven air removal — the load cannot be relied on as sterile |
Unloading and cooling
- Let the drying phase finish; never cut a cycle short to save time.
- Use heat-resistant gloves and the tray handle — trays and instruments are still very hot.
- Let packs cool on the tray or a rack before handling; putting hot packs on a cold metal bench draws in condensation.
- Check every pack: dry, seal intact, indicator changed, label readable.
- Treat any wet or damaged pack as unsterile and reprocess it, then look for the cause.
- Record the cycle printout or log against the load number.
Read next Storing sterile packsWet packs and other common faults
Related guides
Autoclave supply near you
Delivery, installation and training across Malaysia from Batu Caves, Kota Kinabalu and Kuching.
Frequently asked questions
Should autoclave pouches be placed flat or on edge?
Why are my autoclave pouches wet after the cycle?
Can I mix pouches and unwrapped instruments in one load?
How full can an autoclave tray be?
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