A packaging fault at the NHS's primary bone cement supplier has brought production to a standstill, threatening to delay thousands of hip and knee replacement operations across Britain.
Heraeus Medical, which holds a contract worth up to £2billion under the health service's orthopaedic framework, informed officials a critical machine failure at its main manufacturing site has halted output of essential surgical cement products.
The disruption is expected to affect availability for a minimum of two months.
Fifteen different bone cement products are impacted by the issue, including standard fixation cements used to secure artificial joints and antibiotic-containing varieties employed in higher-risk procedures and revision surgeries.
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NHS England has responded by directing hospitals to prioritise trauma and urgent cases using existing supplies.
Officials are understood to have approximately a fortnight of stock available, with an anticipated gap in supply lasting between six and eight weeks.
The health service is actively engaging with alternative suppliers to identify compliant products that can fill the shortfall during this period.
An NHS England spokesman stated: "Following a global supply issue, the NHS is issuing immediate guidance to hospitals to ensure trauma and urgent care can safely continue, enable the use of alternative suppliers where possible, and to support prioritisation of orthopaedic waiting lists based on patients' needs over the coming weeks."
Thousands of hip and knee replacement operations across Britain could be delayed
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Cement already held by hospitals remains unaffected and safe for use.
The news has been described as devastating for those who have reached the front of lengthy surgical queues.
Deborah Alsina, chief executive of Arthritis UK, said: "This is a crushing blow for those individuals who have finally made it to the front of the orthopaedic surgery queue after a long time waiting."
She added: "We trust the Department of Health and Social Care will work hard to address the supply issues given the impact on those waiting in pain whose lives are left on hold."
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A packaging fault at the NHS's primary bone cement supplier has brought production to a standstill
| PAParliamentary figures from February 2025 showed more than 31,000 patients awaiting hip replacements and nearly 50,000 waiting for knee surgery, with average waits stretching beyond six months.
Ms Alsina urged hospitals to contact affected patients swiftly to prevent additional anxiety, noting that Arthritis UK is offering support through its helpline and online community.
The British Orthopaedic Association is collaborating with NHS officials to source alternative cement supplies and minimise disruption for patients.
Fergal Monsell, the association's president, said: "This is a situation that is beyond the control of trauma and orthopaedic surgeons and NHS organisations."
He explained recommended solutions would be guided by safety considerations and clinical need.
Mr Monsell added: "NHS trusts have also been advised to utilise the released theatre time to treat orthopaedic patients where procedures do not require the use of cement."
The association has committed to keeping surgeons informed as circumstances develop.
Heraeus Medical has reassured patients who have already undergone operations using its products that they are not affected, as items already distributed meet quality standards.