LABORATORY & PHARMACEUTICAL FREEZE DRYER: HOW IT WORKS

 

FREEZE DRYER (LYOPHILIZER)

The freeze dryer (lyophilizer) is equipment used in many areas, from research laboratories to the food, pharmaceutical and technological industry. This equipment uses the freeze-drying process to perform its main function and may have some distinct and suitable types according to the purpose for which they were designed. Freeze Dryer, as the name suggests, is a freeze drying method equipment. First the freezing process is applied, then the drying process. In the freeze drying method, which is the most advanced drying method in the world, the frozen product is sublimated under vacuum.

·         Preserves the molecular structure of the product (retains shape).

·         Reconstitution of the product to its in natura form by adding water.

·         Does not change organoleptic characteristics

·         Maintains nutritional value

·         Low temperatures (preservation of protein structures and activity and volatile compounds, maintains the structure and forms pores that facilitate rehydration)

 

But after all, do you know what a freeze dryer is, how it works?

 

HOW DOES THE FREEZE-DRYING PROCESS WORK?

In general, lyophilization is a process of freeze dryer that consists of removing water (and other solvents) from a sample, through the sublimation process, which is the passage from the solid to the gaseous state, without going through the liquid state.

 

This process allows preserving the organoleptic characteristics, such as color, shine, light, odor, texture and flavor, as well as the original form of the product. Therefore, it can be easily restored when hydrated. Thus, as it works at low temperatures, it is also ideal for thermosensitive samples, such as enzymes. Furthermore, it preserves samples by inhibiting enzymatic and oxidative reactions, which normally take place in the presence of water. It also increases the shelf life of products, which can be stored at room temperature for years.

 

At first, to start lyophilization it is necessary that the sample is completely frozen. Soon after the association of low temperature and pressure, it allows the removal of the solvent by sublimation. As a result, a product with a porous structure as well as moisture-free is obtained that can easily be reconstituted by adding water.

 

FREEZE DRYER APPLICATIONS: WHY FREEZE-DRY?

Freeze dryer in the food industry, this method stands out for preserving the nutritional quality of food. The so-called “astronaut food” is a light option (since up to 90% of water/solvents are removed from the product), nutritious and that maintains the flavor and aroma of the product in natura.

 

As well as Freeze Dryer in the area of ​​research and pharmaceutical industries, it stands out for allowing the preservation of enzymes, yeasts and other microorganisms. As well as blood products, cells, vaccines, viruses, serums, algae, among others.

 

Among the advantages of this method are, for example, accurate dosage, low enzymatic activity, easy reconstitution, possibility of sterile manufacturing.

 

As well as the most recent freeze dryer applications are: the preservation of flowers and animals, old documents and books or those recovered from floods, taxidermy, bone banks and tissue for implantation.

 

USES OF FREEZE DRYER (LYOPHILIZER):

·         Food Applications (Coffee, Herbs, Fruits, Nutraceuticals, Vitamins, Extracts, Animal Products, etc.)

·   Pharmaceutical and Biological Applications (Drugs, Enzymes, Biological Agents, Cell and Tissue Applications etc.)

·         Chemistry Applications

·       Museum Recycling (Preservation and recovery of water content such as Books, Wood, Archaeological products, etc.)

 

Do you still have questions about the freeze-drying process or the specifications of Freeze Dryer? Talk to one of Yatherm Scientific experts. Yatherm Scientific is a leading manufacturer and supplier of laboratory and industrial equipment and provide high performance Laboratory Freeze Dryer and Pharmaceutical Freeze Dryer for optimal freeze drying results.

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Lyophilization - The Freeze Dryer Driven Food Revolution

 

Ever since the dawn of time, people have tried to find ways to ensure that food remains safe to store and consume for the longest possible time. In the last few years, the revolution in long term food storage has been let by the process of Lyophilization. In this process, the food is frozen below its triple point and then dried through vacuum process to extract all moisture from food and disperse it elsewhere. This process is done to kill all bacteria and other microbes present in the food item. Once all the microbes are destroyed, the food spoilage process slows down to such an extent that it can be stored safely for very long duration of time. 

Three Step Process:

·        The first step in the process is to freeze the product at a very fast pace. Yatherm freeze dryer is specially prepared to ensure that no ice crystals are formed in the food which may risk insufficient drying activity.

·        The second step is to expose the item to a vacuum which is placed below the triple point of water to extract any moisture which may be left after the freeze steps. This leads to moisture becoming consolidated which is then ready for the next step.

·        Finally, the material is dried out through sublimation which leads to all the consolidated moisture content being sucked out of it and dispersed elsewhere. 

Key Features of Freeze Dryer:

Freeze dryer equipment is designed to be extremely user friendly. The device is equipped with digital PID controller and multiple validation ports. No CFC or HCFC is used in refrigeration to ensure that environment is not impacted at all. The devices have the capability to operate from below -40°C or -110°C temperature and operate in single and dual stage cooling. Devices are available in different ice capacities from 2 to 50 litres.

The machines are fitted with Temperature, pressure and time control system and handles both primary and secondary drying steps with ease. The body is built to resist any kind of corrosion. The display panel is also equipped with an audio-visual alarm system on its display panel for single point monitoring..

The Future of The Freeze Dryer:

The food industry has a bright future because despite all scientific process, there is no alternative to eating and many food items need to be shipped and stored for a long duration. Similarly, with growing economic power of people, choice and quantity of food demand is also expected to grow exponentially. People are looking for more internationally available food items and a global culinary palette is emerging.

This can only be satisfied by freeze dryers which will allow long storage and shipping of food. Lyophilization is a mature technology and can be scaled and adopted very rapidly. It has minimal impact on taste, shape, colour and texture of the food. Yatherm freeze dryer is a cost effective and highly durable product ready to match the growing demand of such products all over the globe. 

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