Batch freeze drying system for food and beverage preservation

Achieve precise and efficient preservation of your food and beverage products with advanced freeze drying technology, enhancing shelf life while maintaining nutritional integrity and flavor.

Processes and Preserves Food and Bioactive Ingredients

The RAY® Freeze Dryer series from GEA offers versatile freeze drying solutions tailored for food, beverage, pet food, and biotech industries. These dryers excel in preserving nutritional value and extending product shelf life through precise sublimation processes. The RAY® batch and continuous freeze dryers accommodate diverse applications, from freeze-dried fruits and vegetables to bioactive products like probiotics and enzymes. RAY® models, such as RAY®1, RAY®125, and RAY® Pilot Plant, process input volumes ranging from 20 kg to 30 tons per day. Integrating energy-saving technologies and automated features, they ensure efficient operation with minimal supervision. The modular design facilitates rapid installation while ensuring scalability and seamless integration into existing production lines. Constructed from robust materials, the dryers support high hygiene standards with optional sanitary designs. Available with CIP systems, these dryers offer easy maintenance, contributing to consistent operational reliability. Customization options and GEA’s engineering support further enhance process optimization, aligning with specific production goals.

Benefits

  • Enhances product preservation and shelf life by maintaining nutritional integrity and flavor.
  • Reduces energy consumption and operational costs with integrated heat pump technology.
  • Facilitates flexible production scaling with modular and configurable capacity options.
  • Simplifies installation and setup, minimizing downtime and associated costs.
  • Ensures consistent product quality with fully automated control systems and precise process monitoring.

General


Applications
Food,Beverages,Ready meals,Seafood,Bioactive products,Pet food,Bacteria,Meat,Fruits,Enzymes,Vegetables,Tea,Instant coffee,Probiotics
End products
Freeze-dried smoothies,Freeze-dried fish,Freeze-dried strawberries,Freeze-dried mushrooms,Freeze-dried pineapples,Freeze-dried leeks,Freeze-dried pet food,Freeze-dried meat,Freeze-dried blackberries,Freeze-dried instant coffee,Freeze-dried snacks,Freeze-dried tea,Freeze-dried vegetable mix,Freeze-dried ready meals,Freeze-dried fruit mix
Steps before
Preparation,Loading product trays,Programming unit,Conveyance of trays using overhead trolley system
Steps after
Unloading product trays,Packaging,Inspection of freeze dried products,Quality control
Input ingredients
fruit,vegetables,pet food,meat,seafood,probiotics,convenience foods,instant coffee,tea,ready meals
Output ingredients
freeze dried fruit,freeze dried vegetables,freeze dried pet food,freeze dried meat,freeze dried seafood,freeze dried probiotics,freeze dried convenience foods,freeze dried instant coffee,freeze dried tea,freeze dried ready meals
Market info
GEA is known for its expertise in engineering innovative and sustainable equipment and solutions, focusing on sectors such as food, beverages, pharmaceuticals, and energy, with a reputation for quality, efficiency, and advanced technological applications in industrial processing.

Technical Specifications


Capacity
20-30 kg/day to 20-30 T/day
Automation
Fully automated
Batch vs. continuous
Batch
Heating plates
Built-in
Vapor condensers
Integrated in unit
Drying time
8–48 hours
Cycle time
24 hours of freeze drying
Product loss
Less than 0.1%
Freezer type
Cylindrical cabinet
Sublimation capacity
High
Temperature control
Precise
Vacuum control
Precise
Energy Usage per Batch
Reduced with high efficiency refrigeration systems

Operating Characteristics


Automation level
PLC / SCADA
Batch vs. continuous operation
Batch
CIP/SIP
CIP 121°C / SIP 135°C
Cleaning method
CIP / Manual
Fast setup and installation
Modular design / Fast installation
Energy efficiency
High efficiency / Energy-saving

Material Compatibility


Cleanability
Easy access for cleaning and maintenance
Density/particle size
0.5–2.5 g/cm³ / 50–1000 µm

Physical Characteristics


Machine footprint
Cylindrical freeze drying cabinet
Discharge method
Front door for loading and unloading product trays
Control panel type
GEA Codex® control and automation system
Compact footprint
Modular design with connections at the rear
Batch size
20-30 kg/day (RAY®1) to 20-30 T/day (6 x RAY® 125)
Heating plates
Included as a part of the complete unit
Vapor condensers
Built into the cabinet as a complete unit
Overhead trolley system
Used for conveying trays
Unit configuration
Batch freeze drying setup

Custom Options


Control panel type
GEA Codex® control and automation system
Integration possibilities
Full batch reporting,data management,and visualization tools
System configuration
Modular design
Capacity customization
20-30 kg/day to 20-30 T/day
Heating system
Integrated heating plates
Condenser integration
Vapor condensers built as a complete unit
Sanitary design
Full sanitary design available