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Instrument reprocessing in the dental practice: 6 steps, 134 °C, limit values for burs and polishers, and how to clean diamond burs the right way.
Instrument reprocessing in the dental practice always follows the same chain for burs, cutters and polishers: pre-clean, clean and disinfect, inspect, package, steam sterilise at 134 °C and store dry. The recommendation of KRINKO and BfArM and the manufacturer's information according to EN ISO 17664 are decisive. The service life of burs is limited mainly by wear in use; for polishers it is a maximum of 10 reprocessing cycles.
The recommendation of KRINKO and BfArM requires a validated, documented procedure based on the risk classification of the instrument. Rotary instruments are medical devices. The practice, as the operator, carries out the classification; the manufacturer describes the procedure in its reprocessing recommendation. Semi-critical means: contact with mucosa or pathologically altered skin. Critical means: the instrument penetrates skin or mucosa and comes into contact with blood or tissue. The suffix B stands for increased requirements, for example because of surfaces that are difficult to access.
The table shows the usual classification of rotary instruments:
| Instrument | Use | Classification (usual) |
|---|---|---|
| Diamond and carbide burs | preparation, restorative therapy | semi-critical B |
| Surgical burs | osteotomy, bone contact | critical B |
| Polishers | polishing of restoration and tooth | semi-critical B |
rotatec instruments are supplied clean but non-sterile. They therefore go through the complete cycle before first use and after every use. Single-use products marked with the symbol ⊘ are sterilised only once before first use.
Reprocessing always follows the same sequence so that no step impairs the effect of the next. It starts as soon as possible, for polishers within 2 hours at the latest.
The table shows the six steps with procedure and note:
| Step | Procedure | Note |
|---|---|---|
| 1. Pre-cleaning | soft plastic or nylon brush, running water | immediately after use so that nothing dries on |
| 2. Cleaning and disinfection | manually or in a washer-disinfector | automated preferred |
| 3. Inspection | illuminated magnifier | cleanliness, integrity, wear |
| 4. Packaging | sterile barrier system | intended for steam sterilisation |
| 5. Steam sterilisation | autoclave, 134 °C | holding time according to reprocessing recommendation |
| 6. Storage | packaged | dry, clean, at room temperature |
Instrument stands are suitable for sterilisation only if the instruments are used immediately afterwards. For storage, they belong in a sterile barrier system.
Automated reprocessing in a washer-disinfector (WD) is standardised and reproducible and is therefore preferable. The manufacturer's reprocessing recommendation specifies which methods, agents and parameters are permitted for which instrument. For rotatec, these are the instructions for use and reprocessing of burs and the instructions for use and reprocessing of polishers. You will also find both under Downloads. For anything not covered there, the instructions for use of the device and the agent apply.
Burs and polishers differ mainly in holding time, temperature and number of cycles. The bur recommendation applies to diamond burs, diamond burs for zirconia, carbide burs, finishing burs and surgery, and the polisher recommendation applies to polishers.
The table compares the values from both recommendations:
| Parameter | Diamond and carbide burs | Polishers |
|---|---|---|
| Immersion time in the solution | maximum 12 hours | according to reprocessing recommendation |
| Ultrasonic bath | with a suitable cleaner | maximum 42 °C |
| Alcohol-based agents | according to reprocessing recommendation | not permitted |
| Steam sterilisation | 134 °C, 4 minutes holding time, 15 minutes drying | 134 °C, fractionated pre-vacuum, at least 3 minutes (Germany: at least 5 minutes) |
| Maximum temperature | according to reprocessing recommendation | 150 °C |
| Reprocessing cycles | limited by wear | maximum 10 |
For burs, the agents must be suitable for rotary dental instruments, otherwise there is a risk of corrosion. Immersion for longer than 12 hours also promotes it. Uncleaned burs must not be placed in fixing agents, for example aldehyde-based ones. With polishers, rubber and silicone react more sensitively: above 42 °C, protein coagulates in the ultrasonic bath, and strong acids and alkalis attack the stainless steel shank. After the 10th cycle, a final sterilisation cycle follows, then disposal with the practice waste.
A diamond bur only stays cutting-efficient if the diamond grains are exposed, so pre-cleaning immediately after treatment is the most important step. Correct reprocessing preserves the diamond density on the working part and extends the service life considerably. Never leave instruments to dry: dried-on residues clog the spaces between the grains and can hardly be removed. This is followed by the ultrasonic bath with a cleaner suitable for rotary instruments, then sterilisation according to the manufacturer's information. How the grains sit in the nickel bond is shown in the article How a diamond instrument is made.
The table shows typical findings during inspection under the illuminated magnifier:
| Finding | Cause | Action |
|---|---|---|
| Residues between the grains | dried on, pre-cleaned too late | clean again, ultrasonic bath |
| Bare spots, grit loss | wear in use | discard |
| Corrosion on the shank | unsuitable agent, immersion time too long | discard |
| Bent shank, chatter marks | mechanical damage | discard |
For diamond and carbide burs, it is not reprocessing that determines the service life but wear and damage in use. If you check for chipping, cracks, chatter marks and bent shanks at every inspection and discard worn instruments in good time, you protect tooth structure, result and patient. For polishers, the limit of 10 cycles sets the framework. High-quality instruments with consistent cutting and polishing performance lower the cost per treatment.
For queries and reports, the marking on the instrument and label counts:
| Marking | Purpose |
|---|---|
| Figure and code number | sorting and allocation |
| Lot number on the label | traceability, queries, product reports |
| Symbol ⊘ | single-use product, sterilise only once before first use |
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Only persons with the necessary expertise, as required by the German Medical Devices Operator Ordinance. Dental assistants acquire this expertise during their training. Anyone reprocessing without relevant training proves their expertise by completing a specialist course.
Cleaning removes blood, protein and working residues from the surface. Disinfection reduces the number of microorganisms to the point where they no longer pose a risk of infection. Sterilisation kills or inactivates all microorganisms, including spores, and requires a clean surface.
Cleaning and disinfection in a washer-disinfector, also known as a thermal disinfector. The device works with a fixed programme of dosing, temperature and time. As a result, every run is identical and can be validated and documented.
The instruments are immersed in a cleaning and disinfection solution approved for rotary instruments. They are then brushed, rinsed thoroughly and dried. The manufacturer of the agent specifies concentration and exposure time, but burs never stay in the solution overnight.
There is no fixed number for diamond and carbide burs. The decisive factor is the condition at the inspection after each cycle. As soon as grit loss, corrosion or a bent shank is visible, the instrument is replaced.
Yes, with a cleaner suitable for rotary instruments. The ultrasonic bath loosens residues from the spaces in the diamond coating that a brush cannot reach. The working parts must be completely covered by the solution.
No. The cutting performance comes from the diamond grains in the nickel bond, not from a ground edge. Once the grains are worn or have broken out, the coating cannot be resharpened and the instrument is replaced.
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