TOWARD A SAFER FUTURE: CHEMICAL-FREE ANTIBACTERIAL PLASTICS
CLAYENS Healthcare, a leading innovator in plastic solutions for the healthcare industry, has achieved a significant breakthrough with its cutting-edge surface functionalization technology.
This method gives antibacterial properties to plastic surfaces without the use of chemicals, by replicating micro and nano patterns from the cavities during injection molding. This advancement holds promising applications not only in the medical field but also in the food industry and other industrial sectors.
Initially developed and validated for hydrophilic, hydrophobic, and anti-friction purposes, this technology has now demonstrated its effectiveness in limiting biofilm growth and reducing bacterial adhesion (bacteriostatic effect), while targeting bacterial elimination (bactericidal effect). By eliminating the need for chemical coatings or additives, it integrates seamlessly into existing healthcare applications, potentially avoiding the need for changes to materials or validation processes, including biocompatibility testing.
“This technology presents unique opportunities to enhance the safety and performance of plastic devices across various environments,” says Matthieu Besse, R&D Health Manager at CLAYENS. “It allows continuous improvement of medical devices or pharmaceutical packaging without significantly altering regulatory files.”
Research has underscored the critical role of the texture/material/bacteria combination in achieving optimal antibacterial performance. Tests conducted internally at CLAYENS and in collaboration with clients have revealed that the efficacy of micro and nano textures is highly material-dependent. For example, textures effective for polyethylene (PE) differ from those optimal for polypropylene (PP), polyamide (PA), or other injectable materials such as crystal PS and PEEK. This highlights the importance of tailoring solutions for each polymer to achieve the best possible results.
CLAYENS Healthcare has developed an innovative experimental approach, as modeling the behavior of the texture/material/bacteria combination remains complex. During tests conducted in compliance with ISO 22196:2011 standards, specimens of various materials were exposed to representative bacteria: Escherichia coli (E. coli) and Staphylococcus aureus (golden staph). The results confirmed that efficacy depends significantly on the interactions between texture and material.
For instance, with the polypropylene/Escherichia coli combination, a specific texture achieved a logarithmic reduction (Rlog) exceeding 2, corresponding to a reduction of over 99% in bacterial count compared to a non-textured surface. Similarly, a tailored texture applied to the polypropylene/Staphylococcus aureus pair achieved an Rlog above 2, demonstrating a comparable 99% reduction in bacterial count. Promising ongoing trials aim to further enhance these results by not only limiting biofilm development but also advancing bacterial destruction.
Conversely, the same texture applied to other materials did not yield comparable results. These findings underscore the necessity for precise optimization of each polymer to maximize bacteriostatic effects and, ultimately, bactericidal performance.
“Our teams continue to explore innovative solutions to address the specific challenges of our clients,” adds Pauline Spard, R&D Engineer. “We managed to achieve advanced bacteriostatic properties by limiting biofilm formation and development, and are now working on bactericidal surfaces.”
About CLAYENS:
CLAYENS Healthcare, representing the healthcare activity of the CLAYENS Group, supports industrial health players (medical devices, pharmaceuticals, and diagnostics) in the development, industrialization, and manufacturing of custom medical devices and plastic components in compliance with international regulatory standards.
CLAYENS Healthcare offers a complete service, from R&D to production, including industrialization, qualification, validation, and regulatory support.
Present in 9 countries, the CLAYENS Group has nearly 5,000 employees and 32 manufacturing sites. The Group's 8 cleanrooms are located in France (ISO7), the USA (ISO8), and Mexico (ISO7).
More information : https://www.clayens.com/healthcare.
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