Rapid Point-of-Care Sterilization of Personal Protective Equipment for Frontline Healthcare Workers

During the COVID-19 pandemic, shortages of filtering facepiece respirators (FFRs), including N95 masks, highlighted the critical need for effective decontamination and reuse strategies. Current decontamination methods often rely on large, expensive equipment, hindering point-of-care application and timely reprocessing. This study presents the design and evaluation of a portable, low-cost system utilizing high-voltage pulsed electric fields (PEF) for FFR sterilization and electrostatic recharge. A novel PEF generator was developed, featuring precise control over pulse parameters and significantly faster rise/fall times compared to existing systems. The generator was integrated into a compact, user-friendly enclosure with custom-designed electrodes. Testing demonstrated that PEF treatment did not compromise N95 mask filtration efficacy, as confirmed by Bacterial Filtration Efficiency (BFE) and Differential Pressure (Delta P) testing conducted by Nelson Labs. Furthermore, in collaboration with the Mayo Clinic, the system's efficacy against SARS-CoV-2 inoculated onto FFR fabric was evaluated. Results showed significant reduction in viral load after PEF treatment short of complete inactivation, comparable to or exceeding the efficacy of traditional sterilization methods but with significantly shorter treatment times. This portable PEF system offers a promising solution for rapid, efficient, and cost-effective FFR decontamination and reuse, potentially mitigating PPE shortages and reducing healthcare costs and waste.Clinical Relevance- During the coronavirus disease-2019 (COVID-19) pandemic, PPE, including filtering facepiece respirators (FFRs), were critical to contain disease spread and protect first responders and healthcare workers on the frontline. Shortages of FFRs, including N95 masks, have led public health agencies to provide guidance in favor of FFR decontamination and re-use as a crisis capacity strategy.