Large amounts of toxic ethylene chlorohydrin can form from chlorine-containing materials in the sterilized product. Excessive temperatures can distort or melt some materials. Rubber can be damaged. Several materials can become odorous. Silicone lubricants become more viscous.
Some adhesives lose significant strength.
Material degradation, which may have been acceptable immediately after irradiation, can continue as the package sits on the shelf. This can become a problem a year or two after irradiation. Thin areas of a package are more sensitive to radiation because of oxidation from the air. Products must be configured in certain ways for certain sterilization methods. This can increase production throughput while also meeting maximum dose requirements.