Case Study

How Queen’s Hospital Burton reduced theatre wrap damage by 85% with smart storage solutions

Working closely with theatre staff, infection control and the Capital Projects team, the hospital partnered with Ocura to design and install a flexible, purpose-built Clini-Store storage system across five theatre preparation rooms with minimal disruption. The result was a step-change in performance, including an 85% reduction in wrap damage, increased storage capacity, and sustained periods with zero torn packs reported.

Challenge: Enhancing patient safety through improved storage

Queen’s Hospital Burton identified an opportunity to improve the integrity of sterile instrument wraps, which are critical to patient safety and theatre efficiency. The existing storage systems, while functional, were increasingly contributing to wrap damage due to design limitations causing disruption to the Theatre’s and sterile services operation by frequent sterilisation and re-wrapping.

Recognising the importance of maintaining sterility and supporting clinical workflows but struggling for years for the funding, the hospital’s Decontamination team has initiated a project to modernise its theatre storage infrastructure which has been approved.

Objectives

Upgrade storage across five key theatre preparation rooms to reduce/eliminate wrap damage.
Implement a flexible solution that could be relocated in future to more centralised storage space.
Enhance daily workflow efficiency for theatre staff in a high-pressure environment.

Collaborative approach with theatre staff at the heart

The project was driven by close collaboration between the Decontamination/Sterile services team, Capital Projects team and theatre staff, who played a vital role in shaping the solution. Initial discussions began at the IDSc Conference, where the Decontamination Leads initially explored innovative storage options and invited Capital Projects to undertake the venture and select the most suitable but competitive solution. That is when Ocura was engaged.

Here’s how we worked together:

Listening to frontline needs: Theatre staff shared operational challenges and infection control priorities over numerous Team virtual calls.

Site survey and feedback: A tailored setup was proposed by us following a detailed assessment on site, with sample racking provided for hands-on evaluation.

Staff and Infection Control input: Drawings and sample racking was provided for hands-on feedback, which Infection control and theatre teams jointly reviewed and approved the final design.

Minimised disruption: Installation was completed in three well-coordinated phases.

Responsive aftercare: All snagging items were swiftly addressed, ensuring a smooth transition.

Results that matter

The installation covered all five theatre preparation rooms across the hospital.

And the impact?

600+ instrument packs stored individually – eliminating stacking and reducing tear risk.
31%^{^} increase in storage capacity compared to previous systems.
79%^* reduction in torn instrument packs (2022 vs 2025)
85%^** reduction in damaged wraps (June 2024 vs June 2025)
Two continuous months^*** without a report of a single torn pack

These results reflect the success of a solution co-designed with those who use it daily.

The right products, purpose-built for theatre environments

The Clini-Store Theatre Bespoke Storage System was installed across all five preparation rooms, featuring:

Easy-access baskets, catheter hooks, sterile instrument shelves for 500 supplements
Colour-coded, wipeable vinyl labels and label holder rails
Custom storage above warming cabinets, suture storage, COSHH cabinet shelves
Under-counter trolley storage, equipment locations, filing shelves

Every element was chosen with infection control, visibility, and usability in mind.

Staff reflections

I first discovered Ocura at an IDSC conference and was really impressed with the quality and flexibility of the racking/shelves in terms of manoeuvrability and option to add more units.

Wendy Kirk, Decontamination Lead/E & F Quality Lead at University Hospitals of Derby and Burton NHS Foundation Trust

After funding had been secured and a round table of companies had been approached, Ocura made it very easy to explore options that were suitable for the site. The quality of the products was excellent and adaptable to the needs of the area.’

Helen Lawson – Clinical Theatre Manager

Final word

Queen’s Hospital Burton’s experience shows how investing in smart, staff-led solutions can deliver lasting improvements in patient safety and operational efficiency. If your hospital is facing similar challenges, we’d be happy to share that experience and expertise that helped teams at Queen’s Hospital, part of University Hospitals of Derby and Burton NHS Foundation Trust.

_{^{^}Average of 91 instrument packs stored per room pre-Installation of Clini-Store.}

_{^*Year to date comparison (Jan – June 2022 (82) vs Jan – June 2025 (17)). New storage was installed only in Main Theatres and this data is a cumulation of all theatres within Queen’s Hospital Burton and Sir Robert Peel Community Hospital.}

_{^**June 2024 (14) vs June 2025 (2). New storage was installed only in Main Theatres and this data is a cumulation of all theatres within Queen’s Hospital Burton and Sir Robert Peel Community Hospital.}

_{^***April & May 2025 Queen’s Hospital Burton reported zero damaged instrument packs.}