Continuous Vacuum Freeze Dryer
Overview
The Continuous Vacuum Freeze Dryer is an advanced, high-volume industrial processing system engineered for continuous-feed production. Unlike traditional batch-loading units that require manual loading, vacuum breaking, unloading, and defrosting cycles, this system utilizes an integrated multi-chamber layout—comprising loading, freezing, primary drying, secondary drying, and unloading zones—linked by specialized vacuum airlock valves.
Model Range & Capacity: Available in CFD-500 (500 kg/24h wet weight), CFD-1000 (1000 kg/24h), CFD-2000 (2000 kg/24h), and fully custom modular configurations.
High Energy Efficiency: Continuous thermal utilization reduces specific energy consumption by 25% to 40% (kWh/kg) compared to batch dryers of equivalent output.
Vacuum & Temperature Performance: Achieves an ultimate vacuum level of < 10 Pa (operational range 20 Pa to 80 Pa) and condenser temperatures ranging from -45 deg C to -75 deg C.
Sanitary Construction: Product contact surfaces feature electro-polished AISI 316L stainless steel (Ra <= 0.4 um), paired with an AISI 304 structural framework (3 mm to 8 mm wall thickness).
Industrial Automation: Governed by a Siemens S7-1500 PLC and WinCC SCADA industrial panel, with 21 CFR Part 11 compliant data logging available for pharmaceutical applications.
Model Series & Technical Specifications
Product Range
|
Model Series |
Input Capacity (Wet Weight) |
Ice Condenser Capacity |
Heating Plates Area |
Primary Application |
|
CFD-500 |
500 kg / 24h |
600 kg / 24h |
30 m2 |
Specialty ingredients, pilot-to-medium production |
|
CFD-1000 |
1000 kg / 24h |
1200 kg / 24h |
65 m2 |
Commercial food processing, pet treats |
|
CFD-2000 |
2000 kg / 24h |
2500 kg / 24h |
130 m2 |
Large-scale instant coffee, bulk FD meals |
|
CFD-Custom |
Engineered to specification |
Engineered to specification |
Scalable modular design |
High-capacity industrial integration |
Key Technical Parameters
Heating Plate Temperature Range: -30 deg C to +120 deg C with a control precision of +/- 1 deg C.
Refrigeration System: Cascade refrigeration utilizing eco-friendly refrigerants R507/R23 and Bitzer/Bock semi-hermetic screw compressors.
Conveyor & Drive System: Magnetic drive sealed conveyor belts or stainless steel mesh belts equipped with variable frequency drive (VFD) speed control.
Vacuum Pumps: Leybold or Edwards rotary vane / dry screw pump packages.
Valves & Instrumentation: Wika pressure transmitters, Endress+Hauser flow meters, and Festo pneumatic valves.
Utility Requirements: Powered by 380V/480V, 50/60Hz, 3-phase electricity. Cooling water requires 25-32 deg C at 0.2-0.4 MPa pressure. Compressed air requires 0.6-0.8 MPa (oil-free and dry).
Instant Coffee Granules: Continuous extraction concentration drying that yields consistent porosity and fast dissolution rates.
Pet Food & Treats: High-throughput processing of raw meat chunks, organs, and formulated kibble while maintaining nutrient integrity without chemical preservatives.
Fruits & Vegetables: Sliced fruits (such as strawberries and apples) and vegetables (such as peas and corn) that retain their original shape, color, and 98% nutrient retention.
Instant Meals (FD Rations): Ready-to-eat outdoor and emergency meal components engineered for rapid rehydration in hot water.
Selection & Facility Integration Guide
To ensure optimal system integration, procurement teams should evaluate the following parameters:
Sublimation Load Calculation
Determine initial and target moisture contents to calculate water evaporation weight per hour (kg H2O/h). Rule of thumb: Ice condenser capacity must exceed the evaporation rate by at least 20% to manage peak loads.
Eutectic Point (Ep) Evaluation
Test product freezing characteristics. Materials with low eutectic points require lower shelf and condenser temperatures (-50 deg C or lower) to prevent structural collapse during primary drying.
Feeding Form Determination
Assess whether the product is liquid (requiring spray granulation or belt spreading), sliced, or particulate to define the appropriate conveyor mechanism and vacuum airlock design.
Facility Integration
Verify factory ceiling height, floor load-bearing capacity (>= 15 kN/m2), and utility access including steam/thermal oil boilers, cooling towers, and heavy electrical feeds.
Customization Options
Multi-Stage Airlock Sealing: Features a dual-valve intermediate buffer chamber preventing vacuum loss during continuous belt feeding and unloading, maintaining chamber pressure fluctuation below +/- 2 Pa during operation.
Chamber Configuration: Multi-zone, temperature-independent heating plates designed for precise thermal profiling throughout primary and secondary drying phases.
CIP/SIP Integration: Automated Clean-In-Place spray balls and Steam-In-Sterilization ports built for strict sanitary compliance in food and pharmaceutical production lines.
Material Handling Customization: Adaptable with ultrasonic cutting modules, vibrating feeder integration, and automated sorting discharge chutes.
Quality Control & Manufacturing Standards
Pressure Vessel Compliance: Chambers are manufactured and certified according to ASME Section VIII Div. 1 (U Stamp) or PED 2014/68/EU standards.
Welding & Inspection: Undergoes 100% radiographic testing (RT) or dye penetrant testing (PT) on all vacuum chamber structural welds, followed by passivation to prevent corrosion pitting.
Factory Acceptance Testing (FAT): Each system completes a 72-hour dry run test verifying vacuum hold capability, refrigeration pull-down speed, and mechanical conveyor synchronization prior to crating.
Pressure Rise Test: In a clean, dry, and empty chamber at < 10 Pa, the pressure rise rate does not exceed 10 Pa/h within a 24-hour test period.
Electrical Safety: Control panels are built to UL508A or CE/IEC 60204-1 standards, wired with numbered terminal blocks and housed in NEMA 4X / IP65 stainless steel cabinets.
Packaging, Shipping & Technical Support
Export Crating: Vacuum-sealed in heavy-duty moisture-barrier foil bags with industrial silica gel desiccants, secured inside ISPM 15-compliant heat-treated fumigated wooden crates.
Component Separation: Fragile instrumentation, vacuum gauges, and glass components are removed, individually cushioned in anti-static foam, and packed in separate reinforced sub-boxes.
Documentation Package: Supplied with P&ID diagrams, electrical schematics, material mill test certificates (MTRs), ASME/PED data reports, and maintenance manuals.
Commissioning & Support: On-site supervision by senior mechanical and automation engineers covers mechanical assembly, utility hookup, vacuum testing, trial runs, and operator training.
Frequently Asked Questions
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