Effects of ventilator tubing corrugation design on condensate accumulation

Abstract Background The use of adequately humidified and heated gas during invasive mechanical ventilation (IMV) is mandatory to prevent complications associated with under humidification. However, condensate formation within ventilator tubing remains a persistent challenge that can compromise ventilation efficiency and patient safety. This study investigates whether the shape of ventilator tubing influences the formation of condensate, focusing on its implications for both non-invasive ventilation (NIV) and IMV. Methods A commercially available adult heated tubing was used as a control group(conventional heated tubing) alongside nine experimental tubing designs with distinct combinations of corrugation angle (non-skewed, left-skewed, right-skewed) and wavelength (narrow, standard, wide). The tubing sets were connected to a heated humidifier, and condensate accumulation was measured at 1, 2, 4, 8, and 24 h under controlled environmental conditions (23 °C–26 °C, relative humidity 40–60%). Data were averaged across three trials, and a two-way analysis of variance (ANOVA) was conducted to assess the effects of design variables. Results By 8 h, inter-tube differences reached 11.8 g, increasing to 42.8 g by 24 h. Two-way ANOVA revealed that wavelength significantly affected condensate buildup (p = 0.016), while skew angle did not (p = 0.126). However, their interaction was significant (p = 0.012). WN showed the highest 24-h condensate accumulation (265.07 ± 6.99 g), whereas SR had the lowest (222.27 ± 22.55 g), outperforming the control (SN: 238.83 ± 4.39 g). Conclusion These findings underscore the pivotal influence of wavelength on condensate formation. Compared with the conventional SN design, SR reduced 24-h condensate by approximately 16.56 g (~ 7%). Tailoring tubing designs based on wavelength and skew angle can help optimize mechanical ventilation performance and potentially enhance patient safety and comfort by reducing condensate-related complications.