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Stability of products and shelf-life is critical in these industries and freeze dryers are important assets. This systematic and proactive maintenance plan is not a thing that would be nice to take care of, but in fact a very much needed thing in case you have a high capacity machine (a machine that is always running or runs a lot). Periodic and proper maintenance ensures the uniform quality of products, large output at minimal cost of operation and extended life-time of the machineries. Ignoring these checks may lead to the errors of processes, batch pollution and the damage that is costly to finish. In this blog, we examine some of the fundamental maintenance procedures that must be contained in any maintenance program of the freeze dryers.
Daily Visual and Operational Inspections
Machine operators should make sure that they check the machines before they start work. Before putting oneself in a cycle, one should take a brief survey of the exterior and space around the unit. Watch leakage of fluid e.g. water or oil in the floor. Check main chamber door and drain seal check whether correctly sealed and closed. During usage, you should be watching the phone to confirm that it is not displaying any suspicious readings or error messages. Check the pressure and temperatures of the control panel and ensure that you are seeing what is in line with the established parameter of your cycle. Each of the vacuum pump and compressor should be audited to determine whether it contains any unusual sounds which could be the initial signs of mechanical defects. These are simple daily habits that are used as the first line of defense against bigger problems.
Cleaning the Condenser Coils
The condenser is the focus of attention in freeze drying and where the water, sublimed from the product, must be collected. With use, condenser coils get a good coating of frost and if you don't defrost them the right way can become covered in dust and dirt. This forms an insulating layer with a very low thermal conductance and thereby greatly diminishes the efficiency of the condenser. The unit has to work much harder to reach that same cooling capacity, consuming more energy and wearing out the compressor beyond its typical lifespan. The coils should be checked and cleaned on a periodic basis, depending on usage and the environment. This is done by, in general, by a complete defrosting process and then a delicate cleaning (with the right chemicals and materials) to remove debris without destroying the small fins that are found on these coils.
Vacuum Pump Maintenance
It is the vacuum pump that forms the low pressure environment for sublimation. Its maintenance is non-negotiable. The most important routine job is frequent oil checking and changes. OPSD does undermine the pump’s ability to pull a deep vacuum and hinders efficiency of the process as well can potentially add contamination to the oil which could in turn, damage the pump from within. Oil needs to be replaced at established periods, which are different depending on the frequency of pump use. Also, make sure there are no oil leaks and that the pump’s belts are properly tightened. Pumps requiring the use of coolant will also need to be checked for their level. An evenly serviced vacuum-pump operates quieter, cooler and more efficient.
Inspecting and Cleaning Door Seals
Seals of door The vacuum in the freeze dryer are kept by the door seals which are usually made by rubber or its analogous polymer. These seals wear out and deteriorate after long-term use; they become weak, cracked, or flat. If the seal is breached due to some damage, there won't be a proper vacuum, and the chamber willnot attain set pressure which would lead to a failed cycle. These seals must be thoroughly scrubbed during scheduled maintenance with plain water to ensure there is no residue or particulate material. They need to be checked on damages or deformities after they get cleaned. Coating the seal faces with a small film of manufacturer recommended vacuum grease will both help to extend the life and give you a better seal when new, however use it sparingly;
Calibration of Sensors and Gauges
The data of temperature and pressure sensors can control all the freeze-drying process and can be programmed. In case of misalignment of the sensors, or their non-calibration any more, the control system does not see. This may lead to either cold or hot running cycles and erroneous applied pressure that will ruin a full batch of product. To ensure that these important tools provide you with the correct readings, calibration of these tools with a known reference solution should be done at fixed intervals. This could be a specialized application which could entail special equipment and even necessitate actual performance by a certified technician pursuant to a preventative maintenance contract. You will need to calibrate your sensors, as sensor accuracy guarantees the ability to repeat the process and the quality of the products.
Scheduled Comprehensive Professional Service
Daily and weekly inspections can be conducted by the trained in-house people but a professional engineer will need to service high-capacity freeze dryer periodically. This annual or biannual service must include an entire system inspection, extensive cleaning, inspection of all safety interlocks and correct functioning. With the understanding they possess of a/c systems, the technician can identify possible issues that would not otherwise be apparent when the system is in normal operation (e.g. checking ref levels or checking the neatness of an electrical connection). It is a preventive measure that will wipe out disastrous failures and guarantee that the equipment will be in a good state in several years.
That is all there is to it, good maintenance is the key to maxing on your large capacity freeze dryer. By the sum total of such daily checks, the custody work and professional visits as a constituent of the preventive maintenance program, you will be able to make sure that valuable property is kept safe and that energy is conserved to prolong the useful life of a big investment.