Coatings

COATINGS

TEKCYTE’S NEW COATING DEVICE CAN REDUCE THE RISK OF BIOFILM. SMALL AND MIGHTY ALONG WITH TONY SIMULA, CEO, TEKCYTE DISCUSS THE IMPORTANCE OF CREATING A SAFER OUTCOME FOR PATIENTS.

NOT S ING IS BELIEVING

TekCyte has developed a biocompatible medical device coating that can be chemically bonded to, for example, a stent or catheter surface. This provides a protective barrier against the body’s natural responses to foreign objects, making implantable devices less visible to the body’s immune system.

Stents and other vascular devices coated in this drug-free coating repel accumulation of platelets, proteins, and cells. This aims to reduce complications from stents such as clotting and restenosis and therefore, more reliable for surgeons and more durable for patients.

“We developed BIOINVISBLE to be easily applied to any existing metal stents. The coating process is scalable to meet future commercial demands, providing medical device manufacturers a reliable, safer and drug-free alternative stent.” says Dr Tony Simula, CEO at TekCyte.

More recently BIOINVISIBLE has also been shown to significantly reduce the risk of biofilm on coated surfaces, which could help infection or device failure caused by biofilm. Helping guard against the development of biofilm reduces the likelihood of later medical complications. At the same time, the protective qualities of this technology also enhance the durability of the medical device that the coating is applied to.

WHAT ARE BIOFILMS? Biofilms are estimated to be responsible for more than 65% of nosocomial infections, almost 80% of chronic infections, and approximately 60% of all human bacterial infections. Biofilm treatment is very challenging because treatment with antibiotics is often ineffective. Implants are very susceptible to the formation of biofilm, which can develop over days, or even over several months.

The safety of any new technology is paramount and according to tests conducted at NAMSA, all studies have successfully shown no evidence of systemic toxicity, irritation, cytotoxicity, hemolysis or sensitivity associated with exposure to BIOINVISIBLE.

“Our research shows that BIOINVISIBLE has the potential to address complications associated with biofilm buildup, without the release of drugs or other active agents,” says Dr Simula.

In fact, TekCyte’s research has shown that catheters and cannulae coated with BIOINVISIBLE could have markedly reduced rates of biofilm from organisms such as Candidaalbicans, Pseudomonas aeruginosa and Staphylococcus aureus.

BIOFILM SIDE EFFECTS Urinary tract infections are one of the most common types of infection associated with catheters and is almost always the result of the development of biofilm. According to the Center for Disease Control in the United States, approximately 75% of UTI’s are associated with a urinary catheter. Several studies have shown that opportunistic pathogenic yeast C. albicans can form polymicrobial biofilms, in vitro and in vivo, and that these biofilms can affect disease course and management. Polymicrobial biofilms such as this are often resistant to antimicrobial drugs. Many researchers have tried to target microbial biofilms to reduce their impact on patient outcomes, however unfortunately current conventional antimicrobial strategies don’t work well to counter biofilm development. By combating the formation of biofilm on medical devices, it helps to reduce the possibility of later complications for patients. This has long been a complex issue for health practitioners, however, we are now on the cusp of great advances due to the active role that BIOINVISIBLE can play in reducing complications from medical devices.

IS BIOINVISIBLE THE ANSWER? Providing better outcomes for patients is at the heart of the ethos of BIOINVISIBLE, which may be especially beneficial for those with pre-existing medical conditions. Those that increase the risk of developing infection and other complications after intervention with a medical device.

“It is clear that BIOINVISIBLE has significant possibilities to address current biofilm challenges and we’re excited by the prospect of working with major device companies to bring to market the first truly biocompatible medical coating.” says Dr Simula.

COATINGS

JAMES RAPLEY, PRODUCT DEVELOPMENT ENGINEER AT MICROBAN, SHOWS HOW ANTIMICROBIAL COATINGS MAKE IT EASIER TO MAINTAIN CLEANLINESS IN MEDICAL ENVIRONMENTS.

CLEANLINESS

The ebb and fl ow of a hospital setting is ceaselessly dynamic, with patients, visitors and staff making up a high volume of foot traffi c travelling through corridors daily. It is no surprise that there is widespread exposure to microorganisms in this environment, and it is a constant struggle for healthcare providers to maintain clean conditions to limit the proliferation of bacteria. Regular cleaning is crucial; however, standard disinfectants retain limited residual activity after application, leaving high touch surfaces vulnerable to contamination through direct contact or airborne droplets.

This is where antimicrobial coatings can augment regular cleaning, as dry-fi lm formulations impart long-lasting and autonomous microbial control to coated surfaces. The recent rise in coating technologies, along with a drive for improved durability, better regulatory status and increased sustainability, has led to developments in antimicrobial additives in line with these goals.

TRANSFORMING WATER-BASED COATINGS Current trends in coating technologies are focused on advancing the durability of coatings and simplifying regulatory processes. In addition, sustainability initiatives in recent years have stressed the importance of features like biocompatibility, biostability and non-toxicity, making water-based coatings that contain fewer volatile organic compounds increasingly appealing to manufacturers. Traditionally, in-can antimicrobial technologies have been employed in aqueous coatings to improve their shelf life during storage, but the benefi ts of these formulations are minimal once the solution has dried, leaving coatings vulnerable to attack by microbes. Therefore, long-lasting dry-fi lm antimicrobial chemistries are integral to improving coating durability.

OVERCOMING THE TECHNICAL CHALLENGES OF ERADICATING SURFACE BACTERIA Dry-fi lm antimicrobial additives for water-based coatings must evolve in line with coating trends, while looking to overcome a range of technical challenges. Dispersing additives into existing formulations has historically triggered aggregation and sedimentation, negatively impacting the appearance of coated products. Similarly, UV instability has reduced clarity and resulted in discoloration and premature surface degradation of coatings in the past. These factors can make coatings unsuitable for transparent applications, reduce the lifespan of coated products, and greatly increase production costs. However, recent innovations in antimicrobial technologies have led to easier integration, avoiding sedimentation, irregularities, or clumping defects, as well as improved stability and durability of formulations.

ENHANCING HOSPITAL CLEANLINESS Antimicrobial coatings, like LapisShield by Microban, work as built-in adjuncts to normal cleaning practices, providing long-lasting protection that does not wear away to surfaces such as hospital curtains, countertops, clipboards and equipment. The active ingredient in this example works by disrupting internal enzymes, blocking metabolic pathways, and creating an inhospitable environment to interrupt bacterial reproduction.

Sophisticated antibacterial additives like this can be integrated into numerous high-touch surfaces within a hospital environment, including wood, metal, polymers and glass, using standard coating processes, such as spraying, roll-to-roll or dip application methods. In fact, studies have shown that built-in antimicrobial treatments in healthcare equipment can inhibit gram-negative and gram-positive bacteria – including antibiotic-resistant MRSA, E.coli and VRE – by up to 99.9 %.

SERVING HEALTHCARE FAR INTO THE FUTURE Incorporating antibacterial additives into hospital surfaces at the point of manufacture is an integral part of ongoing plans to enhance hospital cleanliness. The healthcare segment accounted for 26 % of the overall global revenue share of the antimicrobial additives market in 2021 and is expected to experience the fastest annual growth rate between 2022 and 2030.

Rising demand for autonomous product protection against microbes in a variety of medical products and surfaces – from fl ooring and wall cladding to trolleys and clinical apparatus – means that manufacturers worldwide are seeking to integrate these innovative chemistries into coatings. New antimicrobial technologies that are easy to incorporate, aesthetically pleasing, highly functional and free from heavy metals can transform coatings in healthcare environments, ensuring greater peace of mind for staff and patients alike.

BEFORE AFTER

COATINGS

MARK SCOTT, MARKETING MANAGER AT PEERLESS, EXPLAINS HOW HARD COATINGS CAN IMPROVE SUSTAINABILITY IN THE INDUSTRY.

As the plastic industry, along with all industries, focuses on improvements to sustainability it is worth noting the fact that a solution to improving the sustainability of plastic products has been available for many years yet remains underutilized.

Imagine a specially formulated treatment that provides abrasion resistances to protect the surface of plastic products from scuffs and scratches caused by general, everyday wear and tear. A treatment that provides chemical resistance to plastic surfaces that otherwise could be easily damaged by solvents and chemicals they are exposed to during use. A treatment that can offer additional surface properties such as UV resistance, anti-fog, anti-static, anti-glare, antimicrobial and anti-graffiti properties, to name a few. Such surface treatments significantly extend the lifespan of plastic products, ensuring they are fit for purpose, made to last and potentially eliminating the need for replacement during the products life span, helping to lower carbon footprints in the process.

All these specially formulated properties, which extend the useful life of products can be granted to the surface with the application of hard coatings.

Hard coatings are applied to plastic substrates in a liquid form and cured using heat or UV energy. The level of abrasion and chemical resistance can vary depending on the hard coating’s formulation. Some coatings offer a lower abrasion resistance but in doing so offer an extended life under external weathering conditions.

WHAT ARE HARD COATINGS USED FOR IN THE INDUSTRY? Hard coatings are particularly useful in medical applications such as: • Hard coated hygienic wall cladding and surface covers, incorporating specialist properties such as antimicrobial protection. The hard coating in these applications offers a robust surface to decorative wall coverings to meet the daily wear and tear of hospital corridors, operating theatres, kitchens, toilets/rest rooms, etc. Hard coatings can also be applied to protect the plastic parts used on patient beds and in areas that are subject to daily wear and tear saving on replacement costs. • Hard coated and Anti-Fog PPE providing a tough long-lasting solution for medical visors and goggles, whilst guaranteeing clear vision without fogging up. This helps to ensure the wearer is comfortable and able to keep PPE on at all times keeping them and patients safe. • Antimicrobial hard coatings applied to door furniture such as handles and push plates, offering hygienic surfaces for high traffic areas. • Operating Theatre lighting, with an abrasion and chemical resistant hard coating to allow for regular cleaning of the lighting lens, to ensure optimal light transmission for the life of the product.

HOW CAN HARD COATINGS IMPROVE SUSTAINABILITY? Advances in plastic production and ensuring materials are recycled in recent years, have, and will continue to make a difference, but less focus has been placed on ensuring materials last longer and therefore need to be replaced less often. The use of hard coatings on plastic substrates in many other applications would reduce the need for replacement/ recycling, ultimately reducing the carbon footprint and improving the sustainability of said product or project. Once a hard coated plastic product comes to the end of its useful life, it can still be recycled just the same as the uncoated product would have been, so it’s a win-win scenario.

As more industries start to utilize hard coatings on their plastic products, they begin to understand the many benefits offered. Not just superior surface performance and protection, but also improved sustainability and help to lower carbon footprints due to lasting significantly longer and ultimately reducing costs associated with replacements.