Background. The purpose of this study was to estimate the bias and des
ign effects associated with the Expanded Program on Immunization's (EP
I) sampling design when estimating xerophthalmia prevalence, and to es
timate the savings associated with EPI in terms of distance travelled
within selected clusters. Methods. Computer simulation of the EPI samp
ling strategy was done using maps from a xerophthalmia survey of 40 wa
rds in Sarlahi district, Nepal. Samples of fixed cluster sizes of 7, 1
0, 15, 20 and 25 were compared. The estimated prevalence using the EPI
design was compared with the true prevalence in the 40 wards to estim
ate the bias. The design effect was estimated by taking the ratio of t
he variance under EPI sampling to that of stratified random sampling (
SRS) with fixed cluster sizes. The EPI was also modified by increasing
the distance between selected houses from nearest neighbour to skippi
ng 1-4 houses between selected ones. The difference between the distan
ce travelled within clusters using SRS compared with EPI was weighed a
gainst the bias and increased variance. Results. The prevalence of xer
ophthalmia was 2.8%. The EPI design overestimated xerophthalmia preval
ence by between 0.27% and 1.16%. The design effects of EPI cluster sam
pling within wards varied between 0.73 and 1.35. Neither the bias nor
the design effect was related to distance between households or cluste
r size. Distance travelled within wards was always less for EPI design
s with cluster sizes of 7 or 10. There was no saving in terms of dista
nce travelled for designs with cluster sizes from 15 to 25 if there we
re two or more houses between selected ones. For fixed cluster sizes o
f 15 or fewer, the EPI sampling design using nearest or next nearest n
eighbours is a better choice than SRS in terms of minimizing the dista
nce travelled and the mean square error. Conclusions. The choice of an
optimum method would need to account for the density of clusters and
difficulty of travel between clusters, as well as the costs of travel
within clusters. Based on certain assumptions, EPI with 15 children pe
r cluster would be favoured over examining all children in selected wa
rds unless the travel time between wards was more than 2 days.