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Non-Thermal Atmospheric Plasma for Sterilisation

Introduction

Non-Thermal Atmospheric Plasma (NTAP) for sterilisation represents a breakthrough approach to eliminating microbial contamination, including the most resistant bacterial endospores, prions, and drug-resistant pathogens from food contact surfaces, food packaging materials, medical-grade food packaging, processing equipment surfaces, and even specific food product categories, using plasma generated at atmospheric pressure and near-room temperature. Unlike high-pressure steam autoclaving, gamma irradiation, or ethylene oxide (EtO) sterilisation, all of which impose significant constraints on material compatibility, energy consumption, safety, and regulatory complexity, NTAP delivers effective sterilisation outcomes using only electrical energy and a feed gas (typically air, nitrogen, or argon), producing reactive species that irreversibly damage microbial DNA, cell membranes, and essential enzymes without leaving chemical residues, altering material mechanical properties, or generating radioactive waste. NTAP sterilisation is increasingly adopted in food-grade packaging manufacturing, pharmaceutical food supplement production, and high-care food processing zones requiring validated log-reduction in microbial populations.

Why Choose Kerone Non-Thermal Atmospheric Plasma for Sterilisation

Kerone designs atmospheric plasma units with precise discharge control, stable plasma plumes, and uniform treatment zones. They provide high sterilisation efficiency while ensuring zero chemical residue and minimal material stress. NTAP systems are particularly suitable for surfaces, devices, tools, and packaging lines that require continuous, real-time sterilisation without process interruptions. Kerone’s engineering also supports integration into automated conveyors, robotic handling systems, and cleanroom facilities.
Our NTAP systems are designed with a modular architecture that allows treatment zone length, plasma intensity, gas composition, and exposure geometry to be precisely configured for conveyor-mounted packaging sterilisation, chamber-mode equipment surface treatment, or inline tunnel configurations for continuous product sterilisation. Kerone provides full qualification documentation including IQ/OQ/PQ protocols, operator training, and ongoing plasma performance monitoring services.

Types and Features of Non-Thermal Atmospheric Plasma for Sterilisation

Kerone’s Non-Thermal Atmospheric Plasma (NTAP) sterilisation portfolio includes multiple advanced system configurations designed to meet varied industrial, medical, and packaging sterilisation needs. Atmospheric DBD (Dielectric Barrier Discharge) systems generate wide-area, uniform plasma using insulated electrode arrangements, making them suitable for flat surfaces, packaging films, medical trays, and continuous-sheet materials. Plasma jet arrays produce concentrated, high-energy plasma plumes capable of penetrating complex geometries, irregular surfaces, and intricate device structures with precision, enabling effective sterilisation of tools, implants, and multi-layered surfaces. For large-format sterilisation, surface plasma panels create expansive plasma zones that maintain consistent intensity across broad areas, ideal for conveyor belts, workstation surfaces, and packaging lines in cleanroom or production environments. Inline atmospheric plasma sterilisation tunnels integrate NTAP technology directly into automated conveyors, delivering continuous, high-throughput microbial reduction for packaging materials, food-contact components, and medical consumables without slowing production. Additionally, gas-modulated NTAP systems allow controlled introduction of air, oxygen, nitrogen, or blended gases to fine-tune reactive species generation, enabling targeted sterilisation performance while minimizing material stress or oxidation. Each NTAP system incorporates precision power control, stable discharge characteristics, and food/medical-grade construction, offering residue-free, energy-efficient, and scalable sterilisation for modern industrial applications.

Key Features

Sterilisation at ambient pressure, no vacuum required.
Broad-spectrum microbial inactivation (bacteria, spores, viruses).
Non-thermal operation, ideal for sensitive materials.
High treatment uniformity across complex geometries.
Plug-and-play installation for existing production lines.
Zero water or chemical usage, eco-friendly process.
Adjustable plasma parameters for different materials.
Automation-ready with PLC/SCADA compatibility.

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Future-Ready Engineering Driven by AI & IoT

Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.

Real-Time Monitoring & Control

Continuous tracking of process parameters with instant adjustments.

Predictive Maintenance

Intelligent fault detection to prevent failures before they occur.

Adaptive Process Optimization

Dynamic tuning of operations for maximum output and efficiency.

Cloud Dashboards & Analytics

Unified access to real-time insights and performance trends.

Energy & Resource Savings

Smarter utilization of energy to cut costs and reduce waste.

Secure IoT Connectivity

Encrypted data flow with seamless integration across plant systems.

Applications of Non-Thermal Atmospheric Plasma for Sterilisation

Kerone Non-Thermal Atmospheric Plasma for Sterilisation are suitable for:

Medical devices

Scalpels, syringes, implants, disposable instruments.

Pharmaceutical components

Rubber stoppers, caps, vials.

Food packaging

Films, trays, pouches, bottles.

Industrial surfaces

Belts, conveyors, workstation surfaces.

Electronics

Sterilisation of components without heat damage.

Kerone’s Non-Thermal Atmospheric Plasma Systems provide a powerful, flexible, and eco-friendly sterilisation method suitable for a wide range of industrial and hygienic applications. Their ability to sterilise at ambient temperature and pressure makes them a future-ready alternative to steam, chemicals, and UV systems.