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The device used in order to perform the freeze drying is known as a lyophilizer which is scientifically known as lyophilization. It is the process of freezing a product and evaporating the frozen water in the vacuum- without passing through the liquid stage. It is a mild process that does not alter the original shape, color, taste and nutrition of the product in years without refrigeration. Lyophilizers are used in food, pharmaceutical, nutraceutical and biotechnology industries. At Jiangsu Bolaike Refrigeration Science and Technology Development Co., Ltd. we have over 20 years experience in the production of lyophilizers. Below is the entire introduction of a lyophilizer and its operation.
1. The Core Function of a Lyophilizer
The big contribution of a lyophilizer is that it is able to dry a product without heat destruction. Traditional methods of drying (oven drying, spray drying, air drying) use heat to vaporize water, which may cause shrinking, hardening or degradation of sensitive compounds. Things are done in a very different manner with a lyophilizer. First, it hardens the product. After that it creates a vacuum in the chamber. The vacuum water (ice) directly changes to direct water vapor, which, in the vacuum, is known as sublimation and does not transform to liquid. Frozen coils on cold condensers are used to evaporate and condense the vapor. There is no use of liquid water and this implies that the product does not shrink or lose its structure. The result is a dry and light substance, which can be stored at room temperature and lasts years, and is rehydrated nearly instantly. Lyophilizers of Jiangsu Bolaike are to be effective with a good control of temperature and vacuum in each shelf.
2. Key Components of a Lyophilizer
A lyophilizer is a combination of a number of systems. Product is frozen by the refrigeration system and the condenser coils are cooled. In the pharmaceutical field, temperatures down to -85°C are needed. The vacuum chamber is a pressure vessel which is closed and contains the product shelves. It has to be able to withstand the outside atmospheric pressure but has to hold a close vacuum inside. The vacuum pump pumps out the air and non condensable gases. To cut down cycle times, roughing pumps are used in combination with roots blowers in industrial systems. The heating system is used to deliver uniform and controlled heat to the shelves in primary and secondary drying. Lastly, the control system (usually a PLC with touchscreen interface) tracks temperature, pressure and cycle time and automatically changes settings to achieve optimum performance. All these parts are designed to be energy-efficient and reliable by Jiangsu Bolaike and are made of stainless steel and certified by CE.
3. Types of Lyophilizers for Different Applications
Lyophilizers are available in various sizes to accommodate various users. Household lyophilizers are small countertop devices used to preserve food at home- ideal in preserving garden vegetables, fruits and even entire meals. Laboratory lyophilizers are bench or floor mounted systems that have fine temperature and vacuum control, designed to perform research, pharmaceutical development and small batch nutraceutical production. Pharmaceutical lyophilizers are big, sterile equipment, used to produce vaccines, antibiotics, and injectable drugs in GMP compliant production. These have such features as CIP (clean in place) and SIP (sterilize in place) systems. Lyophilizers used in food are large volume high volume production machines of freeze dried coffee, instant meal, fruits, vegetables, seafood, and herbs. Jiangsu Bolaike produces all four types, including small household units and large production lines with a shelf area of 200 or more square meters.
4. What Products Can Be Processed in a Lyophilizer
Lyophilizers are amazingly flexible. They also process coffee and fruits, vegetables, seafood, meat, dairy and whole ready to eat meals in the food industry. They treat vaccines, antibiotics, diagnostic kits among other injectable drugs in the pharmaceutical industry. They process probiotics, enzymes, dietary supplements, and herbal extracts in the nutraceutical industry. Long term preservation of biological samples (blood plasma, tissues) and even flowers is carried out by lyophilizing. The most important is that the product should be freezable. Lyophilizers, Jiangsu Bolaike are applicable in food, vegetables, fruits, coffee, flowers, herbal extracts, seafood, nutraceutical and biological and chemical products- trusted by customers in Europe, Asia and Americas.
Conclusion
Lyophilizer is a machine which freeze dries products by freezing followed by removal of water in the form of sublimation in vacuum. It maintains structure, color, nutrition and flavor for decades without requiring refrigeration. Refrigeration, vacuum chamber, vacuum pump, heating system and control system are key components. Various scales are used in the household, laboratory, pharmaceutical, and food production. Jiangsu Bolaike has more than 20 years of experience, ISO9001 and CE certified, 56 plus national patents and is providing efficient and energy saving lyophilizers. Get in touch with us today to get the correct lyophilizer to use on your product or to have a factory tour at Changzhou in China.