What is Plasma Indicator Tape?

Plasma indicator tape is a specially designed process indicator for low-temperature hydrogen peroxide plasma sterilization, widely used in hospital central sterile supply departments (CSSD) and other facilities that require strict process monitoring of sterilization procedures. Its primary function is to provide a quick, visible indication of whether an item has been exposed to a sterilization process, helping staff distinguish between processed and unprocessed items.

The tape’s core technology lies in its surface chemical indicator coating. When exposed to a hydrogen peroxide plasma sterilization cycle — typically at temperatures of approximately 45–55°C and lasting 28–75 minutes, depending on the equipment — the tape changes from its original color (commonly off-white or light yellow) to a distinctly darker color (such as brown or black). This color change suggests that the sterilization chamber has likely reached the necessary exposure conditions for plasma sterilization, including hydrogen peroxide concentration, temperature, and time. It is important to note that this indication does not, by itself, confirm sterility, but rather that the process parameters were within the intended range.

Plasma indicator tape is generally made from medical-grade non-woven fabric or specialty paper-based materials, providing good breathability and resistance to the conditions of the sterilization process. The adhesive layer is a low-residue medical pressure-sensitive adhesive, ensuring firm adhesion to packaging materials while avoiding adhesive residue after sterilization. Common widths range from 12 to 25 mm, making it convenient for sealing or labeling various sizes of medical device packages.

In practice, plasma indicator tape offers multiple benefits. It serves as a rapid visual cue to separate processed from unprocessed loads and can act as an early warning if a sterilization cycle is incomplete — for example, due to insufficient hydrogen peroxide injection or plasma activation failure. In such cases, an incomplete or irregular color change immediately signals a process deviation, preventing the use of inadequately processed devices. Compared with biological monitoring methods, which may require up to 48 hours of incubation, plasma indicator tape provides immediate process feedback, significantly improving workflow efficiency in sterilization departments.

Limitations

While plasma indicator tape is an effective and convenient process monitoring tool, it cannot replace biological indicators for sterility assurance. Biological monitoring remains the only method that directly verifies the microbial kill efficacy of a sterilization cycle. Therefore, plasma indicator tape should be used in conjunction with other monitoring systems, in accordance with relevant standards such as ISO 11140-1 for chemical indicators and ISO 14937 for sterilization validation requirements.