Case Study: The Wesley Hospital CSSD Redevelopment

At-a-Glance Summary

The Mission

UnitingCare Health sought to transform The Wesley Hospital’s CSSD into a high-capacity, future-ready sterile services department capable of supporting rapid surgical growth, improving ergonomic safety, and meeting stringent AS4187 compliance requirements.

The Outcome

Working alongside Icon Construction, Emery Industries designed and fabricated a suite of custom stainless steel solutions—including height-adjustable sinks, precision packing stations, and high-throughput loading systems—engineered to the workflow, footprint, and compliance needs of the expanded facility.

The Impact

The upgraded CSSD now supports 25,000+ procedures annually and can reprocess more than 5 million instruments per year, with measurable improvements in workflow efficiency, ergonomic safety, and layout optimisation.

Services Provided

• Design consultation

• Compliance-aligned engineering

• Custom stainless steel fabrication

• Installation support

• Workflow-integrated equipment configuration

The Hero & Their Goal

The Wesley Hospital—one of Queensland’s busiest private hospitals—faced mounting pressure from growing surgical demand and evolving sterilisation standards. The existing CSSD was nearing capacity, with equipment and workflows no longer aligned to the modern sterilisation environment or AS4187 requirements.

UnitingCare Health’s goal was clear: redevelop and expand the CSSD into a state-of-the-art facility that not only met today’s volumes but provided a safe, ergonomic, compliant foundation for the next decade of surgical growth.

The Gap: Operational, Space & Compliance Constraints

Before redevelopment, The Wesley CSSD faced several challenges common to high-throughput sterile processing environments:

• Space limitations restricting workflow efficiency.

• Ergonomic risk, with fixed-height benches and sinks contributing to strain during high-volume reprocessing periods.

• Workflow bottlenecks, particularly in packing and washer loading stages.

• Compliance pressures under AS4187, requiring improvements to cleanability, hygiene, and equipment configuration.

• Integration complexity, as the new processing equipment had to align with construction schedules, mechanical services, and infection control considerations.

These constraints demanded a supplier who could design custom-fitted stainless solutions, de-risk the installation process, and collaborate seamlessly with Icon Construction and hospital stakeholders.

The Game Plan: Custom-Engineered Stainless Solutions

Emery Industries worked closely with the builder, CSSD leadership, and infection control teams to develop a suite of stainless steel solutions tailored specifically to Wesley’s workflow and layout. Every product was fabricated to project-specific dimensions for the expanded 500m² sterile services footprint.

Key Equipment Delivered

1. Height-Adjustable Sinks

Designed to fit Wesley’s processing sequence and meet the ergonomic needs of staff working across long shifts.

• Fully compliant with AS4187

• Motorised height adjustment to reduce back and shoulder strain

• Precision-bowl geometry for optimal pre-cleaning

2. Stainless Steel Wrap & Packing Stations

Purpose-built for high-throughput instrument preparation.

• Integrated monitor mounts

• Clean, open surfaces optimised for wrapping efficiency

• Designed to support consistent, repeatable workflows

3. Rack Loading Units

Engineered for seamless compatibility with washer-disinfector systems.

• Custom alignment for quick loading

• Reduced handling time

• Supports increased throughput with fewer bottlenecks

The Process: From Design to Commissioning

To ensure the project was delivered to the highest standard, Emery followed a structured, collaborative process:

1. Design & Consultation

   • On-site workflow observations

   • CAD modelling to ensure equipment integration

   • Coordination with Icon Construction and hydraulic/mechanical teams

2. Custom Fabrication

   • Manufactured entirely in Australia

   • Built using high-grade stainless steel and welded for cleanability

   • Precision-matched to architectural drawings and site measurements

3. Installation Support

   • Scheduled around construction milestones

   • Adjustments made on-site to ensure perfect fit

   • Zero-defect handover across all custom units

4. Commissioning & Review

   • Final compliance checks

   • Staff orientation and ergonomic calibration

   • Post-handover support for operational refinement

The Gain: A High-Performance CSSD for the Next Decade

The outcome of the redevelopment is a modern, high-capacity CSSD that has transformed the Wesley Hospital’s sterile processing capability.

Results & Impact

• Throughput capacity increased to support 25,000+ procedures annually

• Ability to reprocess over 5 million instruments per year

• Improved ergonomics, reducing strain-related risk for CSSD staff

• Streamlined workflows, decreasing handling and processing times

• Enhanced cleanability and compliance, aligning fully with AS4187

• Future-ready layout, supporting the hospital’s projected surgical growth

About Emery Industries

Emery Industries specialises in custom stainless steel solutions for hospitals, sterilising departments, and high-compliance environments across Australia. With a focus on ergonomics, workflow optimisation, and regulatory alignment, Emery partners with healthcare providers and builders to deliver long-lasting, high-performance infrastructure.

Interested in Partnering with Emery?

If you’re a distributor, builder, or healthcare organisation seeking custom stainless solutions for sterile processing or healthcare fit-outs, our team is ready to help.

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