Batch Vacuum Freeze Dryer
Industrial Batch Vacuum Freeze Dryers
Engineered for primary drying (sublimation) and secondary drying (desorption), our industrial batch vacuum freeze dryers deliver the strict environmental isolation, precise shelf temperature profiling, and repeatable lot traceability demanded by regulated pharmaceutical, biological, and advanced food processing facilities. Designed for integration within cGMP cleanroom boundaries, these systems ensure maximum product yield, sterility assurance, and international regulatory compliance.
Primary Applications: Commercial pharmaceuticals, vaccines, active pharmaceutical ingredients (APIs), biologicals, and specialty food/nutraceutical ingredients.
Shelf Temperature Range: -55°C to +70°C with a tight control precision of ±1°C.
Ultimate Vacuum Pressure: < 1 Pa in a clean, dry, and empty chamber.
Condenser Performance: Lowest temperature configurations ranging from -50°C to -85°C based on multi-compressor cascade setups.
Control & Compliance: Siemens S7-1500 PLC paired with WinCC SCADA, featuring 21 CFR Part 11 compliant audit trails and redundant PT100 sensors.
Product Range & Technical Configurations
|
Series |
Shelf Area |
Condenser Capacity |
Key Design & Application Features |
|
BFD-Series (Pilot) |
0.5 m2 - 5 m2 |
10 kg - 50 kg / 24h |
Mobile frame, interchangeable trays, local PLC/HMI data logging; ideal for R&D, clinical trials, and small-batch APIs. |
|
BFD-Series (Production) |
10 m2 - 50 m2 |
100 kg - 500 kg / 24h |
cGMP compliant, 316L internal finish, hydraulic stoppering; suited for commercial vaccines, injectables, and sterile vials. |
|
BFD-Series (Food Bulk) |
20 m2 - 100 m2 |
200 kg - 1000 kg / 24h |
Heavy-duty product rails, rapid hot-gas defrost, multi-compressor cascade; built for bulk nutraceuticals and food ingredients. |
Chamber & Shelf Materials
Product contact surfaces are constructed from AISI 316L stainless steel, mechanically and electro-polished to Ra <= 0.4 um. Chamber bodies and non-contact internal frames utilize robust AISI 304 stainless steel.
Temperature Uniformity
±1.0°C across all active shelf surfaces during steady-state sublimation.
Vacuum Performance
Down time from atmospheric pressure to 10 Pa occurs within <= 15 minutes.
Refrigeration Architecture
Semi-hermetic screw or reciprocating compressors (Bitzer/Bock) utilizing ozone-friendly HFC/HFO refrigerants (R449A, R507, R23) with plate heat exchangers and electronic expansion valves.
Pressure Vessel Compliance
Built strictly to ASME Section VIII (U Stamp) or PED 2014/68/EU standards according to regional destination requirements.
Application Boundaries & Processing Suitability
Pharmaceuticals & Biologicals
Bulk APIs, antibiotics, live-attenuated vaccines, blood plasma fractions, and diagnostic reagents requiring strict residual moisture limits (< 1.0%).
Biotech & Injectables
Vials, ampoules, and syringes requiring precise hydraulic or pneumatic bottom-ram stoppering under vacuum or inert gas (N2) backfill.
Specialty Food & Nutraceuticals
Probiotic biomass, active enzymes, botanical extracts, and high-value pet nutrition that require original cellular structure and nutrient retention.
Selection Guidelines for Procurement
Calculate Ice Condensing Load
Determine the total moisture weight per batch (W) and divide by the targeted primary drying duration (T). Ensure the selected condenser capacity exceeds the peak sublimation rate by at least 25%.
Determine Shelf Area
Calculate based on container fill depth (liquid fill height of 10 mm to 12 mm for vials, or bulk loading density of 15 kg/m2 to 25 kg/m2).
Verify Site Boundary Conditions
Confirm cleanroom wall integration (pass-through configuration) or specific environmental containment levels prior to placement.
Customization & Engineering Options
Sterilization & Cleaning: CIP spray assemblies with rotary jet heads and pure steam SIP distribution headers equipped with pneumatic diaphragm valves and temperature mapping probes.
Isolation Valves: Pneumatic high-vacuum butterfly or mushroom valves positioned between the drying chamber and internal condenser trap.
Loading Solutions: Manual loading trolleys, semi-automatic push-pull tray transfer mechanisms, or fully automated loading/unloading systems (ALUS).
Quality Control, Shipping & Support Protocols
Manufacturing Verification: Complete material traceability with EN 10204 3.1 mill test certificates, 100% radiographic (RT) or dye penetrant (PT) weld inspections, and factory acceptance testing (FAT) featuring 72-hour continuous thermal mapping and helium mass spectrometer leak testing (< 1 x 10^-6 Pa*m3/s).
Packaging & Logistics: Nitrogen-purged vacuum lines, desiccant packs, IP65-rated moisture barrier foil wrapping, and ISPM 15-compliant fumigated export wooden crating with reinforced structural steel skids.
After-Sales Service: On-site validation support (FAT, SAT, IQ, OQ), critical spare parts inventory readiness, and secure VPN-enabled remote diagnostics embedded in the PLC switchboard.
Frequently Asked Questions
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