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Industrial Freeze Dryers

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

Parenteral preparations refer to drugs using non-oral means of administration. Injectables, such as needles and syringes, are used to deliver a drug into the systemic circulation directly in the veins, muscles, under the skin, or in the tissue.

These parenteral formulations are pharmaceutical dosage forms that have strict regulations on being sterile, pyrogen-free, and free from visible particulate matter including reconstituted sterile powders. Solutions, suspensions, emulsions, and gels with APIs intended for administration by injection are usually supplied in vials, ampoules, pre-filled syringes, or pens to facilitate ease of use.

Injectables

Freezing ready foods is a science in its own right. The process must be performed quickly to retain the quality, but decreasing temperatures too fast forms crystals, reducing shelf-life and distorting organoleptic properties. Apart from industrial freezers, frozen food production technology specialized packaging equipment that protects the items from freezer burn and cold chain degradation.

Frozen food

It goes by many names. Freeze drying, lyophilization, or cryodesiccation is a form of dehydration that involves freezing the product to remove its water content and then removing the ice by sublimation – this means going from the solid to the gaseous state without going through the liquid phase. Freeze dryers are widely used in the pharmaceutical industry to increase the shelf life of products such as vaccines and other injectables. Due to their ability to best preserve the flavors, freeze dryers are used for food preservation in the food industry by dehydrating high-value products such as seasonal fruits or coffee. Industrial freeze drying systems are usually comprised of multiple components including vacuum pumps, stainless steel condensers, some form of heating and lastly, a chamber for drying where the materials are placed and processed.

Batch

Continuous

Industrial

When working with small production batches in pharmaceutical processes, maintaining product quality and batch uniformity is crucial. Traditional drying methods may not suffice for such stringent requirements, making precise freeze drying techniques essential.
<h2>Ensures consistent drying with advanced technology</h2>
The MINIMAX by IMA is a GMP-compliant, small-scale freeze dryer designed to meet the specific demands of handling small production batches. Based on the successful LYOMAX concept, MINIMAX provides scalable lyophilization technologies from formulation to full commercial production. With several configurations available, it offers shelf areas ranging from 1.0 up to 3.9 m², and ice condenser capacities from 29 to 78 kg, with minimum condenser temperatures of –75°C. It is equipped with Process Analytical Technologies (PAT) to optimize drying outcomes and gives a data-rich environment for monitoring. It supports non-aqueous solvents and high-potent products processing and can integrate with isolation technology and automatic vial-loading systems. The patented FUSION™ shelf technology ensures higher-quality heat transfer, enhancing process reliability. Designed with redundancy and configurable options, the MINIMAX provides a reliable and versatile drying solution.

Small-scale freeze dryer for pharmaceutical applications

Formulation technologies are an integral process in many industries such as pharma and food. Chemical mixtures require strict handling to combine the separate ingredients into the homogenized recipe that makes your final product. Formulation technology stores, mixes and subjects the elements to a range processing parameters according to your specifications to develop the base material. The resulting formulas are then weighed, formed, packaged, or sent for further formulation.

Formulation

Lyophilization

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

Powder

solid

Entry level

Pilot

Laboratories often require advanced freeze-drying capabilities to support research and development (R&D) efforts. This includes the need for reliable and scalable systems to handle small production batches and ensure quality and consistency, bridging the gap between lab-scale and GMP production-scale requirements.
<h2>Freeze-dry small batches efficiently and reliably</h2>
The MINIFAST from IMA is a pilot freeze dryer designed to combine the functionality of both bench-top and GMP production scale freeze dryers. With configurations available in MINIFAST 04 and MINIFAST 10, it offers shelf areas of 0.4 m² and 1.1 m² respectively. Utilizing IMA Life's patented FUSION™ shelf design, it enhances performance, reduces operating costs, and increases reliability. The MINIFAST features a robust rectangular chamber made from AISI 304L stainless steel and includes an ice condenser with capacities ranging from 8 kg to 20 kg, condensing temperatures as low as -85°C. Suitable for various R&D and small batch pharmaceutical applications, the system is designed for optimal space utilization with shelf interdistances starting from 80mm.

Pilot freeze dryer for r&d and small batch production

Manual

Managing the stability and longevity of temperature-sensitive pharmaceutical products requires advanced preservation techniques. Freeze-drying is critical in this context, as it removes solvents while maintaining the molecular structure of active ingredients.
<h2>Efficiently preserving pharmaceutical products</h2>
The LYOMAX by IMA is an industrial freeze dryer designed to meet the stringent requirements of the pharmaceutical industry. This freeze dryer offers customizable configurations and sizes ranging from 1 m² to 100 m², accommodating a wide variety of production needs. With shelf cooling capabilities from -55°C to +70°C and condenser cooling between -75°C and +120°C, LYOMAX ensures precise temperature control. It includes patented FUSION™ shelves that reduce energy consumption and enhance heat transfer. Furthermore, the integrated automatic, semi-automatic, and manual loading/unloading systems streamline the process, reducing downtime. Designed to comply with GAMP, cGMP, and FDA guidelines, LYOMAX is equipped with VERISEQ® technology for controlled nucleation and KryoAir, an eco-friendly refrigeration system.

Industrial GMP freeze dryer

Freezing

In the pharmaceutical industry, scaling from laboratory development to full-scale production often involves complex processes that require precise control of conditions. One critical phase is freeze drying, which stabilizes products by removing moisture under low temperatures and pressure.
<h2>Optimize freeze drying from lab to production</h2>
The Lyofast Mini by IMA is a compact freeze dryer designed to bridge the gap between laboratory development, pilot testing, and industrial production. This system is adept at processing initial scale-up batches to test the robustness of freeze drying processes, helping to understand future technology requirements for large-scale production. The Lyofast Mini is equipped with four different configurations, ranging from 1 to 2.8 square meters of shelf area. It features CIP/SIP (Clean-in-Place/Sterilize-in-Place) capabilities, a slot door for RABS/isolator integration, and variable shelf interdistance. Automatic stoppering pressure control and redundant shelf inlet temperature probes ensure consistent and reliable operation. Additionally, it incorporates the Lyomaster compact SCADA system for comprehensive process control. This system is particularly suitable for biotech customers and small-scale production, providing commercial value by reducing energy requirements and downstream production costs.

Pilot freeze dryer for pharmaceutical applications

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Industrial sterilization processes are employed in different industries to completely eliminate all living microorganisms from the final product. For instance, in food processing, sterilization equipment is used to produce a stable product with a long shelf-life by eradicating harmful bio-contaminants. Instead, in the medical field, sterilization technologies aim to prevent the transmission of microbes to patients by sterilizing all the tools and medical devices that come in contact with the patient. Most sterilization equipment, such as autoclaves, employs high-temperature pressurized steam to destroy bacteria and disinfect surfaces from spores. Other methods include radiation sterilization or using chemicals such as hydrogen peroxide for disinfection.

Sterilization

Stabilizing biopharmaceutical products often requires a reliable method to increase shelf life. Traditional preservation techniques may not suffice, especially when dealing with high-value products such as vaccines, antibiotics, or hormones.
<h2>Efficiently stabilizes high-value biopharmaceuticals</h2>
The LYOFAST by IMA is an industrial freeze dryer specifically designed for the biopharmaceutical industry. Unlike conventional systems, LYOFAST uses IMA Life’s patented FUSION™ technology to achieve higher quality and process reliability. The FUSION™ shelves are lighter and more resistant, facilitating optimal heat transfer. Supporting a shelf cooling capability down to -55°C and a condenser cooling range down to -75/120°C, the LYOFAST system accommodates various chamber geometries (cylindrical or rectangular) and configurations, making it suitable for bulk formats or liquid forms in vials, ampoules, or syringes. The system also features a two-stage reciprocating semi-hermetic, water-cooled refrigeration system, and vacuum measurements using an active Pirani type gauge. Its modular design compresses project timelines and reduces lead-times while offering significant cost savings.

Industrial freeze dryer for biopharmaceuticals

liquid

Achieving consistent, high-quality freeze-dried products in pharmaceuticals often requires overcoming challenges such as sterility assurance and long drying times. Traditionally, freeze-drying processes involve multiple stages and extensive material handling, increasing the risk of contamination and downtime.
<h2>Delivers continuous and controlled freeze-drying</h2>
The Lynfinity by IMA is a continuous aseptic spray-freeze-drying system designed to streamline the freeze-drying process from bulk liquid to dried particles. It begins with a controlled spray of liquid product into a cryogenically cooled freezing chamber, creating frozen particles. These particles are then transferred to a drying module where they are heated to promote rapid sublimation, preventing agglomeration. The system ensures total containment from formulation to powder filling, which enhances sterility assurance levels significantly compared to traditional methods. Ideal for pharmaceutical applications, the Lynfinity reduces downtime and operational costs while providing greater throughput flexibility and improved product uniformity. Key highlights include minimized scale-up and scale-down challenges, reduced drying time, and no vapor flow limitations. The compact design also lowers both capital and operational expenditures.

Continuous aseptic spray-freeze-drying system

In pharmaceutical and biotechnological industries, freeze drying is a critical process for preserving sensitive materials. Traditional refrigeration systems often involve toxic and environmentally harmful refrigerants, creating challenges in sustainability and safety.
<h2>Eco-friendly air-based refrigeration for ultra-low temperatures</h2>
The KryoAir from IMA is an innovative refrigeration system that uses air as a refrigerant in freeze dryers. This technology is based on a series of compression, cooling, and expansion steps of air, which can be cooled to temperatures as low as -100°C. Comprised of an expander integrated with a compressor, a primary cooler for heat dissipation, and a heat-recovery heat exchanger, the KryoAir system ensures efficient refrigeration with minimal environmental impact. It combines a novel thermal energy storage system to handle peak heat demands, which is compact and has no moving parts. This system is compliant with environmental regulations and avoids the ozone depletion and global warming impacts associated with conventional refrigerants.

Refrigeration system for freeze drying

Compression

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

In the pharmaceutical industry, maintaining sterile conditions and reducing contamination risk during the loading and unloading of vials in freeze-dryers are critical. Traditional methods often involve manual intervention, increasing the risk of contamination and operational costs.
<h2>Automates vial transfer with wireless communication</h2>
The DA VINCI system from IMA is an automated solution designed for the loading and unloading of vials in industrial freeze-dryers. It features a fully independent, self-driven transfer unit that operates wirelessly. The DA VINCI's stand-alone battery-driven module eliminates the need for actuating pushing mechanisms, allowing for a compact footprint. It communicates wirelessly with the freeze-dryer, ensuring seamless integration. Suitable for both ambient and cold shelf loading, the system operates for up to 8 hours without battery recharging. The DA VINCI system promotes high efficiency with minimal contamination risk, making it ideal for aseptic environments, including open/closed RABS or isolator containment setups.

Wireless vial loading and unloading system for freeze-dryers

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

Unloading

Effective drying of powders and bulk solids is critical in many industrial operations. This process challenges engineers with high energy consumption, maintaining product quality, and ensuring consistency. Advanced techniques are continually sought to address these issues and enhance efficiency.
<h2>Optimize drying processes for various materials</h2>
Hosokawa Micron offers a diverse range of drying technologies suited for both batch and continuous operations. Their portfolio includes vacuum, freeze, and flash drying systems. These technologies support the drying of powders, pastes, slurries, and liquids while ensuring energy efficiency and product quality. Integration of innovative feeding systems maintains constant feed rates, contributing to consistent end-product quality. Additionally, their heating/cooling skids and vacuum skids enhance the versatility of the drying process. Hosokawa Micron’s equipment complies with the latest ATEX directives for dust explosion prevention, ensuring safe operation. Their systems feature robust hardware and software controls for monitoring and optimizing drying conditions.

Drying systems for powders and bulk solids

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

In the pharmaceutical industry, producing free-flowing, sterile bulk pharmaceuticals requires advanced drying technologies. Traditional tray freeze dryers often demand significant manual handling and post-processing, posing challenges in efficiency and product quality.
<h2>Produce sterile bulk powder efficiently</h2>
The Active Freeze Dryer (AFD) from Hosokawa Micron is designed to produce consistent, high-quality free-flowing powders in a single, contamination-free process. This system agitates the material in a specially designed chamber, freezing it to form free-flowing granules regardless of whether the starting material is a liquid, paste, or granular solid. The subsequent vacuum drying process sublimes the frozen water, transforming the granules into fine, dry particles. Heat applied to the vessel jacket ensures an even distribution of temperature throughout the material. With excellent cleanability and minimal labor requirements, the AFD system is suitable for producing antibiotics, APIs, collagens, and proteins. The system is available in three models, catering to different volumes and sublimation capacities.

Pharmaceutical freeze dryer

In the industrial production of instant coffee, maintaining high quality while keeping costs manageable is a key challenge. This involves efficient roasting, extraction, concentration, and drying processes to achieve optimal yield and flavor retention.
<h2>Complete instant coffee processing from roasting to drying</h2>
The DEVEX instant coffee processing plant offers a comprehensive solution covering all stages from roasting green coffee beans to producing soluble instant coffee powder or granulate. These plants accommodate production volumes from 1,000 to 12,000 tonnes per year, making them suitable for large-scale operations. Notable features include high-yield extraction technology that improves green coffee yield, saving up to 1,000 tonnes of green coffee annually on a 5,000-tonne production scale. The aroma recovery process ensures maximum retention of roasted coffee flavors, enhancing the final product quality. Additionally, DEVEX provides customizable steps such as clarification, concentration, and both spray and freeze drying. The freeze drying process uses batch dryers (CFD) for quantities below 250 kg/h and continuous dryers (CCFD) for larger quantities up to 1,000 kg/h. DEVEX also focuses on sustainable production practices by optimizing energy and water consumption to reduce operating costs and environmental impact.

Processing plants for instant coffee production

Clarifying

Concentration

Industrial extraction equipment unlocks the valuable compounds hidden away in natural materials. Automated extraction equipment is applied in the pharmaceutical and cosmetic industries to extract active compounds from medicinal plants or herbs. For example, extracting cannabinoids from cannabis plants. But the process is also fundamental to the food industry, recovering various components like aromas, oleoresins, and proteins.  Considerations for selecting suitable extraction technology include the type of plant material to be processed, the extract's heat sensitivity, and the production volume.

Extraction

Roasting involves extended exposure to heat in an oven or over a fire. Depending on your end product, roasting equipment makes sure that the raw materials you put in undergo even roast intensity before they are transferred for further processing. Some roasting technologies may also be used for other cooking requirements, including toasting and drying. When thinking about roasting, the idea of roasted coffee comes to mind. However, there are a wide array of food products that go through a roasting process. For example, nuts such as almonds and cashews go through a roasting machine

Roasting

When producing high-quality dried food or pharmaceutical products, methods that maintain product integrity and extend shelf life are essential. Traditional drying techniques may not be sufficient to meet the stringent requirements of these industries.
<h2>Facilitate gentle and efficient drying processes</h2>
The drying plants from DEVEX specialize in state-of-the-art vacuum and freeze-drying processes used in the food and pharmaceutical industries. These plants enable the production of high-quality dried products with extended shelf life, reduced transport weight, and low biological activity. The drying systems are adaptable, offering batch or continuous processes depending on the task. DEVEX's unique liquid freeze-drying technology preserves valuable ingredients by gently drying liquids directly from the liquid phase. Thanks to these gentle drying methods, high product quality is ensured. Industries such as food (including dried fruit, vegetables, instant food, and drinks) and pharmaceuticals find these plants particularly beneficial. DEVEX provides custom solutions and expert advice to meet specific production requirements, ensuring efficiency and sustainability.

Vacuum and freeze drying plants for food and pharmaceuticals

In the cannabis industry, preserving the potency and quality of the product is crucial. Traditional drying methods often fail to maintain terpenes, cannabinoids, and other essential compounds due to excessive heat and oxygen exposure.
<h2>Optimized drying process for high-quality cannabis</h2>
The HL600 from Cuddon Freeze Dry is specifically designed for commercial-scale cannabis drying. It boasts a wider shelf spacing and comes with pre-programmed recipes tailored for cannabis products. Based on the FD600GPC model, it offers over five times the shelf capacity of the HL50, making it suitable for large-scale operations. The freeze dryer ensures minimal product degradation and maximum potency retention by using low temperatures and vacuum conditions. Additionally, it supports energy-efficient operations, aligning with sustainability goals. The unit is built by Cuddon and sold by their partner The Original Resinator.

Commercial freeze dryer for cannabis products

In the cannabis industry, preserving the quality and potency of the product during drying is critical. Traditional drying methods often lead to loss of terpenes and cannabinoids, impacting the final product quality.
<h2>Optimizes drying for cannabis products</h2>
The HL50 Freeze Dryer from Cuddon Freeze Dry is specifically designed to optimize the drying process for cannabis. It features a compact footprint but offers a large shelf capacity and wider shelf spacing as standard. The plug-and-play installation and pre-programmed recipes tailored for cannabis ensure ease of use and consistency. Built on the FD100GPC model, the HL50 includes design changes specific to cannabis drying, ensuring that it retains terpenes and cannabinoids effectively. It is an ideal solution for small to medium-sized operations looking to enhance product quality with minimal effort.

Cannabis freeze drying system

When processing cannabis commercially, maintaining product integrity and achieving consistent results is crucial. Challenges include moisture removal without compromising essential oils and maintaining quality during storage.
<h2>Efficiently dries cannabis for optimal preservation</h2>
The HL1800 Freeze Dryer, designed by Cuddon Freeze Dry and sold by The Original Resinator, is tailored for commercial cannabis production. It is based on the successful FD1800GPC model but optimized with wider shelf spacing and pre-programmed recipes. These features ensure cannabis is dried effectively, preserving essential oils and maintaining product quality. Furthermore, the dryer is energy and cost-efficient, aligning with sustainability goals. Configuration options and comprehensive customer support make it suitable for varying compliance requirements across different regions.

Cannabis freeze dryer for commercial use

In industrial food processing, certain products have high sugar or acid content, making them difficult to freeze using traditional methods. This challenge necessitates specialized equipment capable of maintaining lower temperatures to ensure proper freeze-drying.
<h2>Freeze-dry challenging products efficiently</h2>
The FD1800LT Freeze Dryer from Cuddon Freeze Dry is specifically designed for freeze-drying products with high sugar or acid content. With an ice condenser temperature of -55°C and a shelf temperature range from -35°C to 70°C, it ensures optimal conditions for effective freeze-drying. The system includes 19 shelves with a total capacity of 170.5m² and operates using R507 refrigerant. Capable of sublimating 1800 kg of ice within 24 hours, the FD1800LT delivers an average yield of 360 kg of dry product per cycle from 1800 kg of wet product at 80% moisture. The equipment is energy-efficient with an estimated consumption of 1.6 kWh per kg. The product's footprint is 7.20m in length, 2.80m in width, and 2.58m in height, making it well-suited for large-scale industrial applications.

Low temperature freeze dryer for high sugar or acid content products

In large-scale commercial freeze drying, managing significant moisture content and large batches efficiently can be challenging. Ensuring uniform drying while maintaining product integrity in sectors like pharmaceuticals or food industry is essential for success.
<h2>Handle large volumes with precision drying</h2>
The FD1800GPC Freeze Dryer from Cuddon Freeze Dry is designed to tackle substantial freeze drying requirements. With an ice capacity of 1,800 kg and a shelf area of 170.5 m², it suits large-scale commercial applications. It features doors at both ends, each with observation ports for easy monitoring. The system’s performance is shown by its ability to sublimate 1,800 kg of ice in 18 hours, yielding an average of 360 kg of dry product per cycle with 80% moisture content. The shelf temperature ranges from -35°C to 70°C, supporting various product needs. The FD1800GPC also allows heat energy recovery up to 140 kW, making it an energy-efficient choice in its category. The entire system is built with food-grade anodised aluminium trays and includes a separate plant skid for convenience and efficiency.

Large-scale industrial freeze dryer

Handling

In the preservation of products with high sugar or acid content, achieving adequate freeze drying can be a challenge. Conventional freeze drying methods may not suffice, leading to incomplete drying and compromised product integrity.
<h2>Efficiently freeze-dry challenging products</h2>
The FD1200LT by Cuddon Freeze Dry is a low-temperature freeze dryer designed specifically for products with high sugar or acid content. The system employs an ice coil set at -55°C and is operated using R507 refrigerant, allowing it to handle challenging drying tasks. With a shelf capacity of 113.7m2 across 19 shelves, it can sublimate up to 1200 kg of ice in less than 24 hours. Typical operational energy consumption is estimated at 84 kW, making the FD1200LT a reliable choice for efficient freeze-drying. The unit includes 224 food-grade anodized aluminum trays and offers a shelf temperature range of -35°C to 70°C. Cuddon Freeze Dry also offers plant equipment on a separate skid for easy integration into existing facilities.

Industrial low temperature freeze dryer for high sugar or acid content products

In large scale food processing operations, achieving efficient preservation while maintaining the quality of food products is a critical challenge. Traditional drying methods can compromise nutritional value and texture, leading to product inconsistency and waste.
<h2>Efficiently freeze dry large batches of food</h2>
The FD1200GPC Freeze Dryer by Cuddon Freeze Dry is designed for large commercial freeze drying applications, particularly in the food processing industry. The unit features a 1,200kg ice condenser capacity and an extensive 113.7m² shelf area, accommodating 19 shelves. This allows for the processing of significant product volumes in a single cycle. The system can sublimate 1200kg of ice within 18 hours, ensuring rapid and thorough drying. It offers temperature ranges from -35⁰C to 70⁰C, providing flexibility for different product requirements. With a peak power requirement of 150kW and potential heat energy recovery of 110kW, the FD1200GPC minimizes operational costs. The dual door design enhances usability, making loading and unloading more efficient. The large footprint ensures that even expansive processing facilities can integrate this freeze dryer without spatial constraints.

Industrial freeze dryer for large scale food processing

For industries dealing with high sugar or acidic products, traditional freeze drying can be problematic due to these challenging properties. Standard methods often fail to achieve efficient sublimation, leading to inconsistent results and longer processing times.
<h2>Achieve efficient freeze drying at lower temperatures</h2>
The FD100LT Freeze Dryer from Cuddon Freeze Dry is specifically designed to handle products with high sugar or acid content, achieving efficient sublimation at significantly lower temperatures. This model, the smallest in the LT Range, matches the product capacity of the GPC Range but ensures a reduced temperature with its R507 refrigerant-cooled ice coil. With a shelf capacity of 9.1m² across 9 shelves, the FD100LT can sublimate 100kg of ice in under 24 hours. Typical yields include up to 20kg of dry product per cycle from an initial 100kg of wet product at 80% moisture. The unit's energy requirements are practical, with an estimated consumption of 2.4 kWh per kg and an operational power consumption of around 10 kW. The freezer is adaptable for various industries needing precise and efficient low-temperature drying, thanks to its robust -55°C ice condenser and durable food-grade anodized aluminum trays.

Freeze dryer for high sugar or acid content products

In small-scale commercial operations and research and development settings, there is often a need to efficiently freeze dry a variety of biological, pharmaceutical, nutritional, and general food products. This requires a solution that offers consistent performance, versatility, and ease of relocation when necessary.
<h2>Efficiently freeze dry small commercial batches</h2>
The FD100GPC Freeze Dryer by Cuddon Freeze Dry is a versatile solution for small commercial batches and research and development projects. With a 100kg ice capacity and a 9.1m2 shelf area, this plug-and-play model can handle a variety of products, from biological specimens to pharmaceuticals and general food items. The freeze dryer’s compact design allows for easy relocation, making it ideal for facilities that require flexibility. It features optimal shelf temperatures ranging from -35°C to 70°C and an ice condenser temperature of -40°C. The unit is capable of sublimating 100kg of ice in under 24 hours, with an average yield of 20kg of dry product per cycle. The FD100GPC has a peak power requirement of 7.5kW and an estimated energy consumption of 1.5kWh per kilogram, ensuring cost efficiency. Built with food-grade anodized aluminum product trays and a single door product chamber, the FD100GPC offers easy maintenance and robust performance, making it well-suited for a wide range of industrial applications.

General purpose freeze dryer for small commercial batches

In research and development labs, maintaining consistent freeze-drying parameters while handling continuous samples can be a challenge. Frequent stopping for ice removal and the need for manual monitoring disrupts workflow efficiency, leading to increased labor and operational downtime.
<h2>Achieve unlimited ice capacity with automated control</h2>
The Lyovapor L-300 by Buchi is a highly automated laboratory freeze dryer with a unique system for continuous sublimation. This is achieved by using two alternately working condensers that allow the machine to operate non-stop. With an unlimited condenser capacity and a condensing capacity of up to 12 kg per 24 hours, the unit maintains stable parameters including a lowest condenser temperature of -105°C and shelf temperature variation of ±1°C. Additionally, Buchi’s Infinite-Control™ technology provides remote process monitoring and control via a mobile app, ensuring you can manage the drying process from anywhere. The L-300's ergonomic design also includes features like an adjustable display and flexible drying chambers to meet diverse application needs across various industries, such as pharmaceuticals, biotechnology, environmental analysis, and food production.

Laboratory freeze dryer for continuous sublimation

When processing heat-sensitive products such as coffee, fruits, vegetables, or meat, maintaining product quality during drying is essential. Traditional drying methods often lead to oxidation, flavor loss, and higher energy costs, which can be problematic for maintaining clean labels and product integrity.
<h2>Gently dries products with minimal flavor loss</h2>
The DryBand Lyo by Bucher Unipektin is a belt dryer designed for the continuous freeze-drying (lyophilisation) of pre-dried or frozen food pieces, as well as coffee. It handles free-flowing granular products, maintaining high product quality through non-oxidizing, low-energy drying. This system involves a series of belts that convey products in a controlled environment, using independent heating zones and patented radiant plates to optimize drying rates. Feeding rates range from 2 to 4000 kg/h, with heating and cooling surfaces from 0.2 to 325 m², and a heating range of 20 to 180 °C. The vacuum levels vary from 0.5 to 50 mbar, ensuring gentle, efficient product handling. Its closed system design ensures automated operation and cleaning, making it suitable for industries like coffee/tea, fruits and vegetables, meat or seafood, pharmaceuticals, probiotics, enzymes, and infant nutrition.

Continuous freeze drying solution for coffee and food pieces

Blending

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

In pharmaceutical manufacturing, ensuring the stability and shelf-life of active pharmaceutical ingredients (APIs) is crucial. Freeze-drying is a method often used to address these challenges, particularly in the production of vial and panel-packed APIs, by preserving the physical and chemical properties of the products.
<h2>Ensures product stability through advanced freeze-drying</h2>
The LYOCORE freeze-dryer from Austar is designed to meet the rigorous demands of commercial API production. Manufactured according to European quality standards and based on the Quality by Design (QbD) concept, this freeze-dryer ensures compliance with cGMP and FDA requirements. It offers a flexible and high-performance solution for preserving APIs in both vial and panel-packed formats. Key features include an advanced freeze-drying system capable of maintaining product integrity through precise control of temperature and pressure. Furthermore, the system provides efficient moisture removal, ensuring long-term stability and shelf-life of the products.

Commercial freeze dryer for pharmaceutical Api production

In pilot research or small-scale production, efficient lyophilization is critical for preserving sensitive materials. Ensuring consistent freeze-drying for various applications like diagnostic kits, tissue engineering, and bulk product analysis is essential to meet research demands and regulatory requirements.
<h2>Facilitates optimized lyophilization for versatile applications</h2>
The VirTis Genesis Pilot Freeze Dryer, offered by ATS Scientific Products, delivers advanced lyophilization technology suitable for research and small-scale production. This equipment features a compact, free-standing design and is equipped with a full-color touchscreen display for user-friendly operation. It offers extensive configuration options with up to six shelves and temperature controls ranging from -70°C for shelves to -85°C for condensers. The system ensures precise vacuum and temperature uniformity, critical for consistent freeze-drying results. Built with 316L stainless steel, it adheres to high cleanliness standards required in pharmaceutical and biotechnology applications. Ethernet compatibility allows for easy data monitoring, conforming to 21 CFR Part 11 requirements, and ensuring compliance for cGMP processes.

Pilot freeze dryer for research and small-scale production

In peptide production and protein purification, maintaining the integrity of delicate compounds during the drying process is crucial. Traditional drying methods can cause degradation or contamination, making them unsuitable for these sensitive applications.
<h2>Efficient lyophilization of peptides and proteins</h2>
The VirTis Freezemobile™ Manifold Freeze Dryer from ATS Scientific Products offers an advanced solution for peptide production and protein purification. With temperatures reaching as low as -85ºC, this freeze dryer accommodates a wide variety of solvents. Its enhanced pressure controls optimize heat transfer, leading to quicker cycle completion. The free-standing design enables easy installation and mobility. Available with 25L or 35L condenser capacities, it supports large batch processing. Users can also benefit from front-facing oil change modules for effortless maintenance and optional filter traps to protect the vacuum pump from corrosive solvents. The durable stainless steel manifold and adaptor plate make the VirTis Freezemobile™ suitable for both aqueous and organic solvents. Industries ranging from laboratory research to pharmaceutical manufacturing can rely on this robust and versatile piece of equipment.

Laboratory freeze dryer for peptide production

In pharmaceutical and biotech production, achieving efficient and consistent drying of sensitive materials can be a challenge. Many labs require tailored setups to handle diverse products, stringent regulations, and specific operational capacities.
<h2>Customize freeze-drying to your exact needs</h2>
The VirTis Benchmark Production Freeze Dryer from SP Industries is designed to meet the unique demands of different laboratory and production environments. Engineered from premium 316L stainless steel, it offers customizable options to address specific needs without compromising on quality. The system allows you to customize shelf sizes, configurations, and control packages. It features 21 CFR Part 11 compliant software, making it suitable for highly regulated environments. With over 200 units installed worldwide and a reputation for dependability, this freeze dryer is ideal for processing diagnostic kits, active pharmaceutical ingredients (API), nutraceuticals, and more. The system employs Lyos 2.0™ control, which facilitates simplified scaling up from pilot to production stages. Optional clean-in-place (CIP) solutions are also available, making maintenance straightforward and efficient.

Customizable production freeze dryer for pharmaceuticals

In laboratory research and development or small-scale production, precise control over the freeze-drying process is essential. This includes maintaining accurate temperature settings, minimizing downtime, and effectively processing a variety of sample types such as diagnostic kits and organic tissue.
<h2>Monitor freeze-drying cycles with digital precision</h2>
The VirTis AdVantage Pro Freeze Dryer from ATS Scientific Products is an advanced benchtop freeze-dryer designed for diverse applications, including laboratory research, development, and small-scale production. The standout feature of this freeze dryer is its Intellitronics™ controller, which allows you to monitor drying cycles remotely via any email-capable terminal. The compact design optimizes space usage while offering significant capabilities, including -85°C cascade refrigeration and a 6L capacity condenser coil. The unit features precise temperature control with silicone-flooded shelves and offers customizable options for cleanroom configurations. Additionally, the AdVantage Pro includes innovative data acquisition and trending software, integrated performance and leak testing, and flexible recipe customization with up to ten thermal treatments and twelve drying steps.

Benchtop freeze dryer for laboratory and small production use

In diagnostic kit production or tissue banking, freeze drying is essential for maintaining the integrity and extending the shelf life of sensitive biological materials. Challenges arise when trying to balance efficiency, precision, and footprint in laboratory or cleanroom settings.
<h2>Compact customizable freeze drying solution</h2>
The VirTis Ultra 50L and 35L Pilot-Production Freeze Dryers from ATS Scientific Products are versatile freeze-drying solutions suitable for pilot and small-scale workloads. These dryers feature a space-saving, compact design and can be customized with up to 15 shelves, various control systems, and temperature and vacuum sensors, allowing you to tailor the system to your specific needs. With shelf temperatures as low as -70ºC and condenser temperatures down to -85ºC, they handle various applications—from high moisture products like vials and bulk liquid APIs to low moisture items such as diagnostic kits and tissue samples. Besides, the front-facing vacuum pump simplifies maintenance. Available control systems include the Merlin and LyoS 2.0™.

Pilot-production freeze dryers for diagnostic kits and tissue banking

When dealing with time-sensitive tasks like drying archaeological artifacts or recovering water-damaged archival materials, achieving stable and effective freeze-drying becomes crucial. The process must ensure preservation without introducing damage or excessive energy consumption.
<h2>Versatile freeze-drying with adjustable condenser refrigeration</h2>
The VirTis General Purpose Freeze Dryer (GPFD) from ATS Scientific Products is designed for challenging applications such as drying archaeological artifacts and preparing museum specimens. The GPFD offers extensive sample capacity and is available in 25L and 35L configurations, making it suitable for large items. It delivers low-energy freeze-drying cycles and features adjustable condenser refrigeration packages, reaching temperatures of -53°C or -85°C. Optional programmable heating up to 60°C allows for precision control in various freeze-drying scenarios. With its clear acrylic chamber doors, you can continuously monitor the drying process. The freeze dryer also incorporates a mid-cycle defrost option to remove sublimated ice efficiently, reducing turnaround time and preventing common issues like vapor port ice blockages.

General purpose freeze dryer for archaeological and biological samples

Defrosting

Thawing

In pharmaceutical manufacturing, precise control over drying processes is crucial to maintain product stability and extend shelf life. Traditional drying methods can compromise sensitive formulations, making an advanced solution necessary for medium-scale production environments.
<h2>Optimizes freeze-drying for pharmaceutical products</h2>
The Harvest Right Pharmaceutical Medium Freeze Dryer is designed for medium-scale freeze-drying, offering 6.5 square feet of tray space and an advanced 7.2 cfm vacuum pump. This freeze dryer operates with a shelving unit that holds 7 trays, each being 7.5 inches wide, 18 inches long, and 0.75 inches high, with a total ice capacity of 4 liters. Its 3/4 HP motor and 1725 RPM ensure efficient operation. The included pump, with its gas ballast feature, minimizes the need for frequent oil changes, extending up to 30 batches between maintenance. The Industrial Pump outperforms standard versions, providing a deeper vacuum of .05 Pascal under cold conditions and maintaining efficiency even in warm environments. The Harvest Right freeze dryer significantly reduces noise levels to 52 decibels, comparable to a refrigerator, and uses less power at 187 watts. Manufactured by Across International, it is suitable for pharmaceutical applications requiring stringent drying conditions.

Pharmaceutical freeze dryer for medium scale production

In pharmaceutical and laboratory settings, precise freeze-drying processes are crucial for preserving biological samples, pharmaceuticals, and other sensitive materials. Traditional drying methods may compromise product integrity, leading to the need for advanced freeze-drying capabilities.
<h2>Optimize large-scale freeze-drying operations</h2>
The Harvest Right Pharmaceutical Large Freeze Dryer from Across International provides substantial tray space for large-scale freeze-drying. Featuring 10.25 square feet of tray space and eight shelves, each tray measuring 9″ W x 20.5″ L x 0.75″ H, this freeze dryer supports efficient batch processing. It has a 6-liter ice capacity and comes with a factory-tested vacuum pump that guarantees performance at 25 microns or better. The included vacuum pump stands out with a gas ballast feature that maintains clean oil for up to 40 batches before requiring a change. Its industrial pump functions efficiently under both hot and cold conditions with a noise level of 52 decibels, lower power consumption (187 watts), and lower weight (32 lbs) than standard pumps. Additionally, the pump's oil mist filter ensures no oil spray, and its greater durability ensures a longer operational life.

Pharmaceutical large freeze dryer with vacuum pump

Freeze-drying is both a time- and energy-consuming process. In addition to the drying itself, loading the trays in and out of the dryer manually also requires a lot of time. Therefore you need to focus on process and loading efficiency.


<h2>Freeze-dry your berries, coffee, and pharmaceuticals quicker with a higher throughput</h2>
The Quasi-Continuous Freeze Dryer (QCF) from Bucher Merk is for freeze-drying goods in the food and pharmaceutical industry in a semi-continuous way. It has an easy tray-loading solution with trolleys suspended from a top-rail system which makes the product handling process easier and faster compared to fully manual loading.

What is more, it is suitable for batches starting at 200 kg and can go up to 3,000 kg. The QCF, allows you to dry products gently and efficiently while saving on energy costs. The system is unique because it utilizes both contact (from below) and radiant heating (from above) for faster processing compared to traditional methods. You can achieve high product quality by a controlled drying profile, limiting the maximum product temperature and in the same shortening the overall drying time.

It comes with vacuum and heating or cooling systems specifically designed to utilize preferred energy sources and provide the optimum balance between short batch times and energy savings. You have the option to include features such as product weighing, continuous drying observation with cameras, emergency cooling, automatic trolley loading/unloading, and cleaning systems in combination with up- and downstream processes.

Semi-continuous freeze dryer with easy-loading

Organic volatile compounds from fruits, vegetables and herbs are essential to manufacturing flavors, extracts, and pure powders. But elevating temperatures during the evaporation process risks altering their chemical structure and lowering the quality of the final product.


<h2>Gentle freeze-drying for fruit powders, herbal extracts, and flavors</h2>
The DryBand system by Bucher Merk is a dynamic belt dryer designed to dry delicate food ingredients. The material moves through an intermediate vacuum chamber between the top and bottom belt section. The drying unit has a vacuum range of 0.5 to 50 mbar and a feeding rate of up to 4,000 kg/h.

The continuous system can be configured for variable or constant drying with heating plates underneath the belt. A crushing device at the discharge end breaks the dried products into powders after drying. Meanwhile, the vapors are collected in an integrated condenser.

Vacuum belt dryer for fruit, vegetable and herbal extracts

Delicate fruits with high moisture levels, such as berries, risk losing their properties when exposed to drying. Destroying volatile compounds and acids, even under low-impact conditions, leads to a loss of nutrients, flavors, and aromas. Moisture release is critical for extended shelf life, but the technology for making fruit powders must protect the bioactive properties from degrading.


<h2>Maximize retention of volatile molecules in fruit powders and berries</h2>
The Zeodration system by Bucher Merk uses an adsorption method that selectively draws water but retains the natural compounds. The heart of the unit is a reactor made from zeolite, a crystallized clay with a narrow pore diameter. At the same time, this water-trapping material minimizes the release of volatile compounds from fruit and fresh products.

A low-pressure environment of 0.5-30m bar makes the technology suitable for freeze-drying and processing delicate materials like berries, plant extracts, or herbs without compromising their aromas. Meanwhile, the reactor attracts water molecules, reducing residual moisture to 0.5%. Zeodration integrates into vacuum and lyophilization systems and handles batch and belt operations.

Freeze drying system for berries and fruit powders

Extracting the essential acids and compounds from fruits and plants is a complex process. But the drying stage can jeopardize their natural characteristics. The aromas, flavors, and other organoleptic properties of the volatile substances are crucial to producing quality fruit powders and plant extracts.


<h2>Preserve delicate compounds with gentle freeze-drying</h2>
The DryBand system for freeze-drying by Bucher Merk is designed for fragile substances such as fruit powders and plant extracts. The technology treats materials with low-pressure vacuum drying starting from 0.5 mbar, which can go up to  50 mbar.

The belts in the continuous drying system are used in series and products move between the top and bottom for an extended residence time. The freeze-dryer is suitable for lab-scale to large-scale lyophilization with a feeding range of 2 kg/h to 4,000 kg/h n. The system supports automated independent heated zones, and the final section can be adjusted as a cooling zone.

Vacuum belt dryer for instant drink powders

Freeze-drying is a complex and delicate process. If you are searching the market for a freeze-drying unit that conserves all physical and biological properties of products post-treatment, this system would be a suitable solution.


<h2>Automated three-stage EASY freeze dryer for fruits and vegetables</h2>
This EASY Freeze DRYER by Pigo is a world leader in high-quality lyophilization. PIGO have made use of their design and manufacturing experience to provide the market with a truly fantastic unit.

The processing structure of the EASY Freeze DRYER provides a turnkey solution to the entire lyophilization process of a wide variety of products, including fruit, berries, vegetables, meat, seafood, soup blocks, rice dishes and many more.

The three-stage lyophilization cycle guarantees for the treated product to retail its original form, volume, and original structure, as well as all physical, chemical, and biological properties. Depending on the model, the processing capacity ranges from 280-1400kg. EFD 350 being the smallest of units with a capacity of between 280-350kg while the EFD 1400 can process between 1200-1400kg of product.

Industrial freeze-dryer for fruits

Freeze drying can be an expensive and cumbersome process. When dealing with nutraceuticals it is essential to ensure that the products are stable, concentrated and have a good shelf life. There is a need for freeze dryers to have a capacity high enough to yield large quantities of the end product through batch production, such as capsules or fortifiers to be added to dried food.


<h2>Save costs with an increased capacity to freeze dry nutraceuticals</h2>
Siccadania’s FD500 offers an automated and continuous freeze drying production, by arranging several FD500 standard freeze dryer units in a system. The modularized and optimized FD500 standard module is perfectly prepared for the automatic loading and unloading of trays. It therefore requires no manual labour. The modules can be customised in a desired and suitable layout to reach your required output capacity. Its capacity can be increased or decreased easily, by adding or removing FD500 dryer units to or from the system. The automation system can handle up to 20 units.

The automatic freeze dry system is thus a cost efficient, high capacity solution which freeze dries your product while maintaining their chemical structure to confirm they still provide the expected health benefits. It is hygienic and easy to maintain making it suitable for freeze drying in the food, beverage and chemical industry and also of nutraceuticals and dietary supplements e.g. probiotic bacteria, colostrum, enzymes and allergen extracts.

Automatic freeze drying system

Nutraceuticals and dietary supplements can be highly sensitive and need to be protected against external such as temperature fluctuations, oxygen and light. The freeze-drying process for these products requires easy up-scaling parameters such as flow, pressure and temperature.


<h2>High capacity and energy efficient drying solution for nutraceuticals and dietary supplements</h2>
Siccadania’s FD500 provides a modular freeze-drying solution for the process industry. It is a hygienic bulk freeze dryer which offers you high quality and energy-efficiency. It has an external condenser which can be separated from the drying chamber. It comes with electrical heating elements which ensure uniform temperature gradient and pressure across the entire tray surface area. This freezer is virtually maintenance free. It has been configured with special attention to up-scaling parameters such as flow, pressure and temperature to enable easy up-scaling. They are certified with either 3.1, FDA and/or FCM.

The industrial food freeze dryer is suitable for the food, beverage and chemical industries and for drying nutraceuticals and dietary supplements e.g. probiotic bacteria, colostrum, enzymes and allergen extracts.

Industrial food freeze dryer

Freeze drying is a complex and time-consuming drying process which requires maintaining the quality of the product. It can be a delicate and expensive procedure requiring high levels of hygiene. A pilot freeze dryer designed for product formulation and scale-up workshould thus help maintain the high quality and shape of products too sensitive for conventional drying processes.


<h2>Hygienic freeze drying system maintaining high product quality standards</h2>
Siccadania’s F30 Pilot Scale Freeze dryer is typically used for dehydrating high value goods, such as nutraceuticals, foods, pharmaceuticals and instant coffee. It is a hygienic bulk freeze dryer with an external condenser which can be separated from the drying chamber. It uses electrical heating systems for the sublimation process. This secures a uniform temperature gradient and pressure across the entire tray surface area maintaining the product quality. No matter how complex your products may be, it is designed to provide an optimised freeze-drying solution while keeping in mind the highest levels of hygiene and sanitation.

The pilot scale freezer is especially suitable for preserving most of the coffee flavour while manufacturing instant coffee, maintaining the shape and quality of rehydrated food products and delicately drying probiotic bacteria, enzymes, algae etc.

Pilot scale freeze dryer

Freeze drying is the most gentle and aroma protective method of drying, widely used in the coffee industry, but also with applications in the food industry and pharmaceutical sector. Specialist continuous freeze drying plants are bespoke designed to meet your exact requirements and deliver a superior end product.
<h2>Continuous belt freeze dryer for gentle handling of delicate product</h2>
The Devex continuous vacuum belt freeze dryer is the ideal solution for continuous freeze drying of granulates. It allows gentle batch feeding and discharge via vacuum sluices to preserve product quality and minimize mechanical handling - perfect for delicate products where maximum retention of aroma, taste and colour is vital such as coffee products, pharmaceuticals, fruits and herbs.

A bespoke Devex freeze drying plant can handle the full product cycle: foaming, freezing, granulation, sieving, sublimation inside the belt dryer, ice condensation, heating system and high-vacuum technology.

Continuous belt freeze dryer

Freeze dryer designed for aseptic and small-scale production of high-value products.


<h2>Industrial freeze dryer in a compact envelope</h2>
Lyotris from Telstar Life-Sciences is a lab scale production freeze dryer designed for the production of small batches of high-value pharmaceutical products. With a 1m2 loading surface and capacity for approximately 1,600 10R-type vials or 30 liters of bulk product. It has been specially designed for aseptic production in vials or in bulk and its novel fascia and door design provides easy isolator integration.

The GMP laboratory freeze dryer comes with all  the necessary components for an automatic cleaning (CIP) and steam sterilization (SIP) processes, filter integrity testing (WIT) and also incorporates an advanced SCADA system which includes Telstar's patented ‘Lyometrics' system; providing advanced real-time information on the freeze-drying process.

GMP laboratory freeze dryer

Pure steam is defined as the steam which when condensed becomes WFI quality water in accordance with European and US Pharmacopoeia specifications.


<h2>Low energy solution when steam is not yet available on site</h2>
The PSG-E electrical pure steam generators consist of a vertical pressure container, in the form of a column. Electrical elements are installed at the base to heat the water. The steam flows vertically upwards, but due to the effect of gravity the water droplets do not exit the chamber. The water is supplied preheated in a tank, also containing electrical elements, where degassing occurs. The system is supplied as a compact unit on a skid, with all components readily accessible.

The PSG-E from Telstar Life-Sciences is a generator capable of effectively separating pyrogens, which are used for the production of pure steam. Clean steam is defined as the steam produced from water free from additives.

The most common applications for this device is in the pharmaceutical industry and in biotechnology for autoclave sterilization feeding and for routine SIP sterilization in production reactors, freeze dryers, and production line filters and pipes.

Electrical pure steam generator

Designed to perform clinical trials, pilot, and small scale or large scale industrial drying processes, in accordance with the strictest GMP and Regulatory standards and in line with the latest freeze drying technology trends.


<h2>The right balance between specification, quality, cost and lead-time</h2>
The Lyonomic Series from Telstar Life-Sciences are state of the art freeze-drying systems, designed and engineered modularly to provide a comprehensive range of standard models and in-factory options.

Telstar freeze drying shelf inner channel design ensures high product homogeneity during the freezing, primary and secondary drying stages. The SCADA supervisory, control and data acquisition system designed by Telstar, allows the user to readily interpret the machine's operation and obtain information on the process required for decision making and batch reporting, all in compliance with FDA 21 CFR part 11 electronic record guidelines.

GMP freeze dryer

For either bulk format or liquid in vials, ampoules or syringes, the Lyomega units are designed for freeze drying high value products, such as: vaccines, cytostatics, antibiotics, biologicals, hormones, active ingredients, reactives, etc.


<h2>Integrated and customized solution for pharmaceutical production</h2>
The Lyomega from Telstar Life-Sciences offers design flexibility to tackle all the requirements for each project. Customization capabilities cover a wide range of engineered solutions, including two-door pass-through design and sub-doors for product loading and unloading at a constant level. Internal or external condenser systems can also be configurated in a horizontal or vertical position, adjacent to or below the chamber. Refrigeration systems range through a double stage or cascade reciprocating compressor, screw compressor or liquid nitrogen and a full range of customized CIP systems are also available.

Custom engineered freeze dryer

A multipurpose unit in the research and development field. Some of the most common applications are galenic formulation, freeze drying experimentation, taxidermy, underwater archaeology, aliquot preservation,  diagnosis and other research.


<h2>Start your research with this multipurpose high-performance device</h2>
The LyoQuest laboratory, multipurpose and R&amp;D freeze dryer from Telstar Life-Sciences has been designed as a multipurpose unit for the research and development field. It is a small freeze dryer, more compact than most but in spite of its small size, its capacity is quite unbeatable. A state-of-the-art control system and a range of specially designed accessories make the LyoQuest a benchmark in its category.

The unit's design offers the best performance in the least possible space. Suitable for laboratories: compact and easy to install, solidly designed laboratory equipment. On a functional level, cooling management ensures optimum performance.

Multipurpose and R&D freeze dryer

Designed for biological, pharmaceutical and food products formulation and "scale up" work.


<h2>Best performance for technology transfer activities and work in advanced R&amp;D Centers</h2>
The LyoBeta from Telstar Life-Sciences is a freeze drying unit for biological, pharmaceutical and food products formulation and "scale up" work, facilitating transfer technology to the R&amp;D centers and production. It is a high performance unit with a GLP design that allows for performing the entire freeze drying process fully automatically as well as accurately monitoring it. Very easy to clean, stainless steel chamber, condenser and plates; includes industrial components, such as sensors, vacuum pump, exchangers, etc.

Some of the most common applications are production in pilot plants, functional food research, preservation of diagnosis kits, small batches for clinical trials and so on.

Pilot freeze dryer for scale up

Particularly suitable for research centers requiring greater freeze drying capacity. Some of the most common applications are galenic formulation, freeze drying experimentation, aliquot preservation, taxidermy, experimental food and so on.


<h2>The laboratory freeze dryer that is easy-to-use</h2>
The LyoAlfa from Telstar Life-Sciences is a compact laboratory freeze dryer. It comes as a console and is mounted on casters which make it easy to install. The unit is very flexible, allowing for the simultaneous freeze drying of bottles, vials or bulk products through the connection of different manifold systems or a chamber.

It is available in two models LyoAlfa 6 -50, with a final condenser temperature of -50 ºC; and LyoAlfa 6 -80, with a final condenser temperature of -80 ºC. This enables a higher freeze drying speed and is much more suitable for working with biological samples or products with very low eutectic or collapse points.

Compact laboratory freeze dryer

The laboratory-scale active freeze-drying is used for dehydrating high-value products that are too sensitive for conventional drying processes. The product is dried by freezing and subsequent sublimation of ice formation, typically in vacuum and at low temperatures, in a small laboratory and pilot plant scale, enabling a smooth transition to the production plant.


<h2>Start innovating with freeze-drying technology</h2>
The 1-liter laboratory-scale freezer dryer from Hosokawa Micron is quicker and less labor-intensive than traditional tray-type freeze dryers. It offers the possibility of producing loose and free-flowing powder at low temperatures and low pressures, all in one vessel. Ideal for testing and simulating processes, the lab unit is "plug and play", including controls and all necessary equipment for reliable operation in your laboratory environment. Ideally suited for pharmaceuticals like antibiotics, collagens, APIs and electrolytes; food industry and special materials like nanomaterials, polymers, ceramics, pigments, fillers, limestone, catalysts, glass powder and salts.

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Laboratory scale active freeze dryer

Freeze dryers

When it comes to vegan alternative plant-based sources, we always think about replacing meat and dairy. But have you ever thought of replacing food additives such as gelatine, an animal-derived ingredient? Agar-agar is emerging as a seaweed-based alternative. The appeal of agar-agar is that it doesn't need to be refrigerated and can stay at room temperature; it is insoluble in cold water and dissolves well in liquids at over 90° Celsius. You find it in powder format for most industrial applications. But agar-agar processing also delivers flakes or threads for food production.

Agar-agar

Brewers' grain, also known as brewers' spent grain or BSG, is the residue of malt and beer production. This brewing by-product is sometimes wasted causing an important environmental impact, nevertheless, with the circular economy in mind, brewers' grain processing can turn waste into value mainly for the feed and food industry, tackling some of the sustainable development goals (SDGs).

Brewers grain

Around a third of your natural protein composition is collagen. But the human body still finds good use for more of it, whether to reinforce joints or aid digestion. Collagen powder processing breaks the chains of amino acids into smaller units, allowing them to be consumed at higher concentrations without changing your diet.

Collagen powder

Fruit dehydration is the earliest form of food preservation, with the earliest written record of dried fruits dating back to ancient Mesopotamian tablets, which contain the world’s earliest known recipes. Today, some of the most popular dried fruit snacks are raisins, dates, mango, pineapple, prunes, figs and apricots. Dried fruit processing equipment helps preserve the nutrients and sweetness of the fruit and prolongs its shelf life.

Dried fruit

Drying meat was the prevalent method of conserving meat cuts when food could not be chilled. But dried meat products developed into delicacies and remained a culinary mainstay long after the functional need for preservation was answered with refrigeration. The ancient techniques have been replaced by dried meat processing equipment, but the time-honored recipes remain unchanged.

Dried meat

The click and puff of inhalers is a universal signal for respiratory conditions. Inhalers quickly grew into preferred drug delivery systems for asthma and COPD. Dry inhaler powder formulation produces a more stable drug than liquid dosage forms. Moreover, inhaler ingredients are more resistant to bacterial growth.

Dry inhaler powder

Echinacea, also known as coneflowers, are brightly hued flowers with distinguished, cone-shaped flower heads. Over 200 medicines in the world are derived from coneflower extracts. Echinacea processing was introduced by Native Americans who were interested in the plant's medicinal qualities.

Echinacea extract

Elderberry falls squarely in the category of superfoods. Every part of the plant (flowers, berries, and bark) is loaded with vitamins, antioxidants, bioflavonoids, and other compounds. However, cyanide in the plant could be lethal if consumed raw, making elderberry extraction processing complex.

Elderberry extract

Koala bears diet exclusively on eucalyptus leaves. But the large concentration of cineole in the tree keeps most other predators at bay. Humans, though, discovered ways to extract the substance and use it as a remedy against inflammations and other diseases. The eucalyptus oil production process keeps evolving to maximize yields, ensuring enough eucalyptus forests for koalas.

Eucalyptus oil

The fishmeal powder market forecast shows that its global market value will reach USD 10.3 billion by 2025. Expanding since 2019, at an annual growth rate of 6.5%. Fishmeal powder production has strong business potential with the increase of applications in animal feed, pet food, and fortified foods.

Fishmeal powder

Only one percent of the entire plant species on the planet produces essential oils, but that amount has found its way into various products, from perfumes to foods. Flower extraction systems are similarly diverse, and picking the right ones depends on the organic material and the final product.

Flower extract

A juicy piece of fruit evokes images of sunlight and warmth. But manufacturers take the reverse route and freeze the harvested products to keep their nutritious mix of minerals, fibers, and vitamins intact. Frozen fruit processing equipment takes temperatures down to around -18 °C, giving the foods an extended lease of life. Many smoothies, jams, and purees we consume are the fruit of frozen labor.

Frozen fruit

Food powder is the result of drying and pulverizing food. It has been around since the astronauts when out to space. Fruits have a short shelf life and are difficult to preserve due to their high water content.  Fruit powder processing allows you to keep the nutrients of the fruits for a longer time, even off-season.

Fruit powder

What’s the only living connection between our present world and the age of dinosaurs? The ginkgo biloba plant. Also known as the maidenhair tree, it is regarded as a living fossil and has been around for more than 200 million years. Ancient civilizations in China were already mastering ginkgo processing centuries ago and the tradition soon flourished around the world.

Ginkgo extract

Panax ginseng is a medicinal plant with a long history steeped in myth. The term “panax” itself is derived from a Greek word for “panacea” or “cure all”. As ginseng processing technology continues to develop, this famous traditional extract keeps finding new applications.

Ginseng extract

Ground cinnamon

<span style="font-weight: 400;">Any coffee-drinker can agree that a cup of coffee in the morning can brighten up their day. As the most convenient way of making coffee, many people choose to make coffee at home. Whether you want to make Moka coffee or filtered coffee, you need ground coffee that is grind appropriately for the coffee brewing method of your choice. These ground coffee are manufactured by roasting and grinding processes. </span>

Ground coffee

Hyaluronic acid is a natural lubricant found in all mammals. An effective humectant, its molecules can hold a thousand times their weight in water. However, hyaluronic acid extraction is a complex biotechnological process that requires a specialized manufacturing technique.

Hyaluronic acid

Do you know that the famous classical music composer and pianist Ludwig van Beethoven insisted on drinking a cup of coffee made from exactly 60 pieces of coffee beans? Currently, around 50% of the world’s green coffee beans undergo processing through instant coffee manufacturing equipment to produce instant coffee. The process requires roasting, grinding, brewing, and heating to obtain the extract; the coffee extract will either go through a spray drying process or a freeze-drying process.

Instant coffee

Insulin is a hormone that controls blood glucose levels produced by the beta cells in the pancreas. As a medication, insulin was discovered by Frederick Banting and Charles Best in 1921, for which Banting was awarded a Nobel Prize in 1923. The insulin production process involves manipulating the biological precursor to insulin and cultivating it inside bacteria using specialized technology.

Insulin

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

The word parenteral comes from Greek and means outside the intestine (para=outside and enteron=intestine). In fact, when it comes to parenterals, we are referring to those dosage forms that are administered directly into the bloodstream using a hypodermic needle, avoiding going through the gastrointestinal tract. Using parenteral filling equipment, parenteral solutions are placed in containers such as vials, syringes, or ampoules.

Parenterals

Pharmaceutical cartridges are glass containers of cylindrical shape, suitable for liquid or solid pharmaceutical dosage forms. Generally, these are designed for a specific apparatus such as pre-filled syringes and autoinjectors. Drugs that can be placed in cartridges using a pharmaceutical cartridge filling equipment include insulin, dental anesthesia, and other emergency drugs for allergies.

Pharmaceutical cartridges

The billions of microbes living in our gut have a significant impact on gastrointestinal health, mood, and behavior. Every individual develops their microbiome community. Probiotic processing technology makes sure that harmful bacteria never outnumber good citizens.

Probiotics

It took the scientific community almost 70 years to agree on the name ‘protein’ and discard the popular alternative, proteid. But protein powder processing still needed another five decades to be commercialized in the 1950s. Once extraction and purification could be industrialized, protein powder soon became a basic staple supplement.

Protein powder

Many pet owners consider themselves parents of furry babies, meaning they consider their pets as family rather than companions. Consequently, pet owners are getting more concerned about their pets’ health and actively demanding a healthy diet. To respond to this market demand, there is a rise in raw pet food production, in which ingredients stay in a more natural state refraining from ultra-processing them and avoiding using preservatives and synthetic additives.