Cold Plasma for Sterilization
Kerone’s Cold Plasma Sterilization Systems utilize advanced non-thermal plasma technology to eliminate microorganisms at room temperature without damaging heat-sensitive materials.
Engineered precision for Cold Plasma for Sterilization.
Kerone’s Cold Plasma Sterilization Systems utilize advanced non-thermal plasma technology to eliminate microorganisms at room temperature without damaging heat-sensitive materials. Cold plasma, an ionized gas containing electrons, ions, radicals, and UV photons, effectively disrupts microbial cell walls, DNA structures, and metabolic pathways.
This makes it a leading solution for sterilizing medical devices, food packaging, pharmaceuticals, laboratory tools, and high-value materials that cannot withstand conventional sterilization methods. Kerone designs these systems with precise plasma generation control, uniform exposure, and customizable process parameters, ensuring fast, chemical-free, and eco-friendly sterilization.
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.
Continuous tracking of process parameters with instant adjustments.
Intelligent fault detection to prevent failures before they occur.
Dynamic tuning of operations for maximum output and efficiency.
The thermodynamic architecture of our Cold Plasma for Sterilization incorporates advanced thermal modeling and computational fluid dynamics (CFD) to ensure optimal heat and mass transfer across the entire processing zone. By precisely controlling thermal gradients, air velocity profiles, and direct energy delivery mechanisms, the system achieves uniform treatment while preventing localized overheating, product degradation, or thermal stress. This balance of intensive heat transfer and controlled retention time ensures maximum operational throughput with minimal specific energy consumption.
Built with heavy-duty structural engineering and sanitary metallurgy, each unit is manufactured to withstand continuous 24/7 industrial operating conditions. Contact surfaces are finished in high-grade stainless steel (SS 304, SS 316L, or corrosion-resistant alloys) with sanitary mirror-polish options, CIP/SIP washdown provisions, and hermetic chamber sealing. This guarantees full compliance with stringent international hygiene, CE machinery directives, and cGMP standards across food, pharmaceutical, specialty chemical, and heavy manufacturing applications.
Proprietary control algorithms ensure strict process repeatability, while built-in safety interlocks and electromagnetic shielding comply with international CE and OSHA standards. Full process development support — including material loss tangent testing, moisture sorption isotherms, and pilot trials at our Ambernath R&D facility — ensures the selected technology matches your exact industrial throughput goals.
Product & Systems Gallery
Explore authentic high-resolution photographs of industrial machinery, pilot trial rigs, and continuous turnkey processing installations engineered by Kerone Engineering Solutions for Cold Plasma for Sterilization. Each system is fabricated at our ISO 9001:2015 certified manufacturing facilities with precision laser cutting, robotic welding, and stringent Factory Acceptance Testing (FAT).
Cold Plasma for Sterilization
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Cold Plasma for Sterilization
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Cold Plasma for Sterilization
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Cold Plasma for Sterilization
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Cold Plasma for Sterilization
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Cold Plasma for Sterilization
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Cold Plasma for Sterilization
Click to view high-res50+ Years of Thermal Engineering Leadership.
Since 1976, Kerone Engineering Solutions has delivered over 5,000 custom-engineered thermal and process installations across 50+ countries. In technical collaboration with premier global institutions like CSIR-CEERI and University of Nottingham research partnerships, we design and manufacture high-efficiency machinery that minimizes production downtime and cuts operating expenses.
Unlike standard off-the-shelf equipment suppliers, Kerone operates a complete pilot-scale testing facility at our KRDC Ambernath center. We validate your exact raw material properties — determining moisture sorption isotherms, specific heat capacity, and dielectric behavior — before finalizing equipment sizing, ensuring zero risk during industrial scale-up.
Engineering precision, built into every system.
Non-thermal Sterilization Suitable
Non-thermal sterilization suitable for heat-sensitive products.
Active Plasma Species Providing
Active plasma species providing broad-spectrum microbial inactivation.
Uniform Plasma Distribution
Uniform plasma distribution for complete surface coverage.
Rapid Sterilization Cycles
Rapid sterilization cycles with low energy consumption.
Zero Toxic Residue
environmentally safe process.
Adjustable Process Parameters
Adjustable process parameters for sensitive applications.
Compatible
Compatible with medical devices, packaging films, instruments, foods.
PLC Automation
PLC automation with recipe control and process logging.
Powered by AI, Machine Learning & Smart IoT Integration
Modern industrial processing requires unprecedented thermal precision, energy efficiency, and operational agility. Kerone equips each system with high-speed industrial edge computing controllers, multi-spectral non-contact infrared pyrometry, and proprietary closed-loop machine learning algorithms that continuously analyze process parameters in real time.
The intelligent automation stack monitors dynamic changes in incoming material load, bed thickness, moisture content, and environmental factors. In response, our algorithms dynamically adjust heater power arrays, generator frequency, conveyor drive velocities, and exhaust dampers within milliseconds — entirely eliminating product burn, under-processing, or thermal hotspotting.
Seamlessly integrated with factory-wide SCADA and enterprise ERP architectures via native MQTT, OPC-UA, and Modbus TCP protocols, our systems deliver complete digital recipe control, remote diagnostics, predictive maintenance alerting, and tamper-evident batch logs compliant with global FDA 21 CFR Part 11 and cGMP standards.
Adaptive Heat Modulation
Neural algorithms detect material thermal variations in real time (<50ms response) and tune generator frequency and power arrays automatically.
IoT Cloud Telemetry
Continuous bidirectional telemetry stream via MQTT/OPC-UA protocols directly to centralized plant SCADA, MES, or mobile engineer dashboards.
Predictive Maintenance
Monitors magnetron cathode current, vibration frequency signatures, and differential filter pressure to schedule AMC maintenance before failures occur.
Quality & Batch Traceability
Automated digital recipe execution, multi-stage temperature ramp/soak curves, and cryptographically signed electronic batch logs compliant with 21 CFR Part 11.
Engineered for High-Value Industrial Sectors
Tailored thermal and process configurations across continuous manufacturing lines.
Medical devices
Provides residue-free sterilization of catheters, syringes, implants, tubing, and diagnostic components without thermal damage.
Surgical instruments
Sterilizes metal and polymer-based instruments with uniform plasma exposure and rapid turnaround time.
Food packaging
Decontaminates plastic films, trays, pouches, and containers without altering mechanical or barrier properties.
Pharmaceutical components
Sterilizes vials, stoppers, caps, elastomers, and contact surfaces used in aseptic processing.
Contact surfaces
Ensures microbial decontamination of conveyor belts, work surfaces, and high-touch industrial points.
Laboratory equipment
Sterilizes petri dishes, pipettes, lab tools, and sensitive instruments without degradation.
Biodegradable materials
Treats eco-friendly packaging and biopolymers without melting, deformation, or chemical contamination.
Polymer films & electronics
Safely sterilizes thin films, sensors, circuit components, sensors, and microdevices that cannot withstand heat or moisture.
Configured to Your Process Window
Technical parameter envelopes across industrial manufacturing and engineering architectures.
Frequently Asked Questions
Engineering answers regarding equipment sizing, integration, and process performance.
It is a non-thermal process that uses ionized gas species to destroy microorganisms without heat or chemicals.
Bacteria, viruses, fungi, spores, and multi-drug-resistant species.
Yes, it is widely used for surface sterilization without affecting nutritional or sensory attributes.
Plastics, metals, polymers, medical-grade materials, packaging films, and electronics.
No, cold plasma does not use chemical agents.
Typically, a few seconds to minutes, depending on the microbial load and system design.
Yes, all Kerone cold plasma systems support PLC automation and recipes.
Routine inspection of electrodes, power supplies, and process chambers.
It works through ionized gas containing electrons, ions, radicals, and UV photons, which physically disrupt microbial cell walls and DNA rather than relying on high temperatures.
No, it's chemical-free and leaves no residue, so films, trays, and pouches keep their original mechanical and barrier properties after treatment.
Atmospheric systems work at normal pressure, which suits continuous-flow sterilization of surfaces or packaging. Vacuum systems create a controlled low-pressure environment, better suited for intricate medical devices or porous materials needing deeper penetration.
Cycles typically range from a few seconds to a few minutes, depending on the microbial load and the specific system configuration used.
Yes, that's a major advantage. Biodegradable packaging, biopolymers, and other heat-sensitive materials can be sterilized without melting or losing their shape.
It's effective against bacteria, viruses, fungi, spores, and even multi-drug-resistant species, giving fairly broad-spectrum protection.
Let’s Engineer the Right Process.
From application trials to full-scale production systems, our engineering team works with you to develop the right thermal processing solution for your material, throughput, and production requirements.