At Eco Ninjas, we take pride in our products — in particular our badge designs for their quality, safety, and aesthetic appeal. Over the last two years, we have conducted rigorous testing and research which helped us rule out numerous other designs due to infection control concerns, longevity, and practicality.

Our yellow badges with black text are highly visible and provide the best colour contrast so clinicians' names and roles are easily readable. This colour contrast also supports staff and patients with both cognitive and visual impairments.

Why Testing Matters

Thorough research and testing in healthcare product development are essential in ensuring the safety, efficacy, and quality of new healthcare garments intended for operating theatres — to confirm that they are fit for purpose and can be used, ordered, and maintained easily and effectively.

Before a new product is introduced into the healthcare setting, it must undergo extensive testing to assess its safety profile. With our badge hats, this included evaluating potential risks — one of which we identified was the badge falling off into the sterile field. We had a 'peel test' conducted by TWI in Cambridge. The results concluded: 'The supplied badge and hat fastening system is suitable for its designed use as the badge can be separated and reattached to a clinical hat many times without a noticeable change in performance or risk of failure.'

Cleaning and Degradation Testing

A frequent question from customers is whether badges can be cleaned effectively without detergent affecting the print or badge itself. We had a degradation test conducted to demonstrate how robust our badges are after being exposed to various cleaning detergents common to healthcare settings. The outcome determined: 'The mechanical performance of the treated polyester badges was not affected by the exposure in the selected cleaning solutions.'

More recently, we had wash testing done by a commercial laundry company to confirm that our hats do not tangle, show only minimal colour fade, and that fresh and dried blood splatter was washed out effectively with no change to the press studs or hats.

Microbial Research

Disposable theatre caps have been worn since the 1990s and are considered by some to offer a reduced risk of cross-contamination. However, a microbial study performed with Birmingham University reached a striking conclusion: there were more microorganisms present on an unworn, disposable theatre cap than on a reusable cap worn for a full 8-hour shift.

The study confirmed that disposable hats can become contaminated when presented in an open box for users to dip their hands into, and may also be microbially contaminated on receipt as they are not marketed as sterile.

Ruling Out Earlier Designs

One of our previous designs featured a plastic pocket integrated into a fabric hat, allowing paper, card or laminated badges to be slotted in. On deeper inspection, we found that moisture could easily get trapped behind the plastic during laundering and develop into mildew — too high a risk in a surgical setting. The plastic windows also cracked after washing. They would not be sustainable or offer a financially viable alternative, so back to the drawing board we went.

Our Commitment

At Eco Ninjas, we have conducted a comprehensive series of studies to assist decision makers in implementing the best products into operating theatres. We have been led by the outcomes of our research to manufacture the most sustainable and cost-effective products — products we hope will make a positive impact for medical staff and patients alike.