Correction of sensor crosstalk error in Exhalyzer D multiple-breath washout device significantly impacts outcomes in children with cystic fibrosis

Nitrogen multiple-breath washout is an established technique to assess functional residual capacity and ventilation inhomogeneity in the lung. Accurate measurement of gas concentrations is essential for the appropriate calculation of clinical outcomes. We investigated the accuracy of oxygen and carbon dioxide gas sensor measurements used for the indirect calculation of nitrogen concentration in a commercial multiple-breath washout device (Exhalyzer D, Eco Medics AG, Duernten, Switzerland) and its impact on functional residual capacity and lung clearance index. High-precision calibration gas mixtures and mass spectrometry were used to evaluate sensor output. We assessed the impact of corrected signal processing on multiple-breath washout outcomes in a data set of healthy children and children with cystic fibrosis using custom analysis software. We found inadequate correction for the cross sensitivity of the oxygen and carbon dioxide sensors in the Exhalyzer D device. This results in an overestimation of expired nitrogen concentration and consequently, multiple-breath washout outcomes. Breath-by-breath correction of this error reduced the mean (SD) cumulative expired volume by 19.6% (5.0%), functional residual capacity by 8.9% (2.2%), and lung clearance index by 11.9% (4.0%). It also substantially reduced the level of the tissue nitrogen signal at the end of measurements. Inadequate correction for cross sensitivity in the oxygen and carbon dioxide gas sensors of the Exhalyzer D device leads to an overestimation of functional residual capacity and lung clearance index. Correction of this error is possible and could be applied by reanalyzing the measurements in an updated software version.NEW & NOTEWORTHY We investigated the sensor accuracy of a prominent nitrogen multiple-breath washout (N₂MBW) device (Eco Medics AG, Duernten, Switzerland) as a possible cause of lack of comparability between outcomes of different MBW devices and methods. We identified an error in the nitrogen concentration calculation of this device, which results in a 10%-15% overestimation of primary outcomes, functional residual capacity, and lung clearance index. It also leads to a significant overestimation of nitrogen back-diffusion into the lungs.