Freeze-drying is a technique that uses the principle of sublimation to dry. It is a process in which the dried material is quickly frozen at a low temperature, and then in a suitable vacuum environment, the frozen water molecules are directly sublimated into water vapor to escape. The product obtained by freeze-drying is called lyophilizer, and the process is called lyophilization. The substance is always at a low temperature (frozen state) before drying, and ice crystals are evenly distributed in the substance. The sublimation process will not be concentrated due to dehydration, avoiding side effects such as foaming and oxidation caused by water vapor. The dry substance is porous in the form of a dry sponge, its volume is basically unchanged, and it is easily soluble in water to restore its original shape. To the greatest extent, prevent the physical, chemical and biological denaturation of dry substances. The freeze dryer is composed of a refrigeration system, a vacuum system, a heating system, and an electrical instrument control system. The main components are drying oven, condenser, refrigeration unit, vacuum pump, heating/cooling device, etc. Its working principle is to freeze the dried item to below the triple point temperature first, and then directly sublime the solid water (ice) in the item into water vapor under vacuum conditions, remove it from the item, and dry the item. After pre-processing, the materials are sent to the quick-freezing warehouse for freezing, then sent to the drying warehouse for sublimation and dehydration, and then packaged in the post-processing workshop. The vacuum system establishes low-pressure conditions for the sublimation drying chamber, the heating system provides sublimation latent heat to the material, and the refrigeration system provides the required cold energy to the cold trap and the drying chamber. This equipment adopts high-efficiency radiant heating, and the material is heated evenly; it adopts high-efficiency water traps and can realize rapid defrost; adopts high-efficiency vacuum unit, and can realize oil-water separation; adopts parallel centralized refrigeration system, multi-channel cooling on demand, working conditions It is stable and energy-saving; it adopts artificial intelligence control, which has high control precision and convenient operation. Xinyu Instrument Network's quality requirements for freeze-dried products are: unchanged biological activity, uniform appearance and color, full shape, firm structure, fast dissolution rate, and low residual moisture. To obtain high-quality products, you should have a more comprehensive understanding of the theory and technology of freeze-drying. The freeze-drying process includes three stages: pre-freezing, sublimation and re-freezing. Reasonably and effectively shorten the freeze-drying cycle has obvious economic value in industrial production.
Structure
The vacuum freeze dryer consists of a drying box, a refrigeration system vacuum system, a media heat exchange cycle system, an automatic control system, a pneumatic system, and an in-place cleaning and disinfection system.
Drying oven
The drying box is a vacuum-sealed low-pressure container. The materials are all stainless steel, which can withstand positive and negative pressures and meet the requirements of steam sterilization. The sealing is made of high temperature and low temperature resistant silicon rubber. The insulation layer is made of closed bubble elastic heat insulation materials.
1) Box body: a rectangular box body with high space utilization rate is adopted. The bottom is equipped with a drainage port, and an observation window is opened on the side. Spray inlet connector.
2) Shelves: The energy needed to cool and open the food is transmitted to the shelf through the heat exchange medium, and then to the food. The shelf adopts a special hollow plywood, which has high strength and good airtightness. The shelf components are installed in the freeze-drying box through the bracket. A board layer should be set up as a heat radiation compensation board to ensure that the food space in the box is under the same temperature environment. In addition, both sides and back of the shelf are installed Block the rails to prevent food pans or food from falling off the shelf.
3) Box door: the cylinder automatic locking device is adopted. Ensure the vacuum required during the decompression process inside the box. When the vacuum pump is working, the butterfly room is opened. The air and water vapor in the vacuum drying chamber pass through the water trap to capture moisture and enter the vacuum pump. The exhaust port of the vacuum pump discharges the system. The exhaust port of the vacuum pump is equipped with an oil mist trap. To prevent the smoke in the exhaust gas from polluting the indoor environment. In order to prevent water vapor from entering the pump, the system is equipped with a gas ballast valve, which is opened during the drying process.
Compared with the conventional method, the freeze-drying method has the following advantages:
* Many heat-sensitive substances will not be denatured or inactivated.
* When drying at low temperature, the loss of some volatile components in the substance is small.
* During the freeze-drying process, the growth of microorganisms and the action of enzymes cannot proceed, so the original properties can be maintained.
* Since the drying is carried out in a frozen state, the volume is almost unchanged, the original structure is maintained, and concentration does not occur.
* Since the moisture in the material exists in the form of ice crystals after pre-freezing, the dissolved inorganic salt substances originally dissolved in the water are evenly distributed in the material. During sublimation, the dissolved substances dissolved in the water are precipitated, which avoids the phenomenon of surface hardening caused by the precipitation of inorganic salts on the surface due to the migration of the internal moisture of the material to the surface in the general drying method.
* The dried material is loose, porous, and sponge-like. After adding water, it dissolves quickly and completely, and restores its original properties almost immediately.
* Since the drying is carried out under vacuum, there is very little oxygen, so some easily oxidizable substances are protected.
* Drying can remove more than 95% to 99% of moisture, so that the dried product can be stored for a long time without deterioration.
* Because the material is in a freezing state and the temperature is very low, the temperature of the heat source for heating is not high, and the normal temperature or low temperature heater can meet the requirements. If the freezer compartment and the drying compartment are separated, the drying compartment does not need to be insulated, and there will not be a lot of heat loss, so the use of heat energy is very economical.
shortcoming
As the saying goes, there is no perfect technology. The main disadvantage of vacuum freeze-drying technology is its high cost. Because it needs vacuum and low temperature conditions, the vacuum freeze dryer must be equipped with a vacuum system and a low temperature system, so the investment cost and operating cost are relatively high.
application
Vacuum freeze-drying technology has a wide range of applications in the fields of bioengineering, pharmaceutical industry, food industry, material science, and deep processing of agricultural and sideline products. The freeze-drying of medicines includes two parts: Western medicine and Chinese medicine. Freeze-drying of western medicine has developed to a certain extent in China, and many larger pharmaceutical factories have freeze-drying equipment. In terms of injections, freeze-drying processes are used more, which improves the quality and shelf life of medicines, and brings benefits to both doctors and patients. However, there are not many varieties of freeze-dried medicines, the product prices are high, and the drying technology is not advanced. In terms of traditional Chinese medicine, it is currently only limited to the freeze-drying of a small amount of Chinese medicinal materials such as ginseng, velvet antler, yam, and cordyceps. A large number of Chinese patent medicines have not yet adopted the freeze-drying process, which is far behind foreign countries. A few years ago, Japan launched the "Western Preparation of Chinese Medicines", which changed the boiling method of Chinese medicines, solved the traditional Chinese medicine cannot be made into injections or tablets, and also solved the problem that Chinese medicines do not cure acute diseases. Therefore, the freeze-drying process of Chinese medicines in my country And product research has great potential to be tapped. In the field of biotechnology products, freeze-drying technology is mainly used for the production of drugs such as serum, plasma, vaccines, enzymes, antibiotics, hormones; biochemical inspection drugs, immunology and bacteriological inspection drugs; blood, bacteria, arteries, bones , Skin, cornea, nerve tissue and various organs for long-term preservation.
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Freeze Drying machine
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Unit
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Production for Batch
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LTDG-1
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LTDG-50
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LTDG-75
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LTDG-100
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Nominal Area
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m2
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1
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50
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75
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100
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Capacity
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Area of the heat shelf
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m2
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1.08
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59.9
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89.9
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110.1
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Tray Area
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1.02
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50.2
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75.8
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101
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Tray Size
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mm
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780*510*37
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Pallet No.*Skip
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6pcs*1
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64pcs*2
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64pcs*
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64*4
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Total Volume Dehydration (Max
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Kg/batch
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15
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1000
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1500
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2000
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Basic Parameter
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Heating Shelf
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Width
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mm
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540
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Length
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mm
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1630
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3260
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4890
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6520
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Number
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17*2
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Volume of Drying Library
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mm
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2200*4760
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2200*7390
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2200*10020
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2200*12650
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Heat Mode
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Radiation
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|
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Heating Shelf Space
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75
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Heating Shelf Range
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°C
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Room Temperature-120°C
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Heating Shelf Cooling rate
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°C/min
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≥5°C/min
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Heating Shelf heating rate
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°C/min
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≥3°C/min
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Condenser Lowest Temperature
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°C
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≤-45°C
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System Lowest Pressure
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Pa
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≤13.3
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Pumping Rate
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min
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10.01*105Pa-133Pa≤15min
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Basic Supply
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Cooling Water qty: ≤30°C, 0.15-0.2MPa
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m3/hr
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0.9
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30
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48
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68
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Total Power
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kw
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8
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75
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100
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160
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Steam Consumption
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L/hr
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220(100)
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450(200)
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670(280)
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900(340)
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Compressed air consumption:07-1.0Pa.0.9
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L/hr
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0.45
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Water Consumption: 50°C, 0.10-0.20MPa
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kg/batch
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5
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10
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10
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15
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Nominal Area
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m2
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1
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50
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75
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100
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Matching Cold Storage
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Cooling Water qty: ≤30°C, 0.15-0.2Pa
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m3/hr
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0.9
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8
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10
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13
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Total Power
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kw
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8
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12
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19
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23
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SERVICE
We have established some overseas agent office to make the after-sales serivce already ,so it can will be service client in fast response .also in our headquarter service team ,there is a expert team which can support client in 7*24 hours .
1. Customer inquiry and consultation (URS documents)
2. Confirmation of treatment plan (DQ documents &PID Drawing)
3.Quotation offer with the technolgy document (Quotation PI )
4.Engineering and Manufacturing (Prodcution &Quality inspection )
5. Product inspection (FAT documents)
6. Delivery arrangement and loading work (full set Shipment documents)
7. After-sales service (OQ,PQ ,SAT documents)
FAQ
1.What about your factory?
Our factory is located in Wenzhou city ,Zhejiang Province and have more than 15 years experience on machinery making.
2.How will your company control the equipment quality ?
We have a qualified expert team ,we will inspect every production proceed .also Machines will be tested in our plant before shipment .
3.How long the warranty will be?
We provide 1 years warranty for the machine running ,but we will afford whole -life service for the machine .
4.Which kind payment do your company do now ?
We accept Western Union, T/T ,D/P,D/C and irrevocable L/C payable etc.
5.Can we become your distributor in our country?
Yes, we very welcome you! More details will be discussed if you are interested in being our agent.
6.Why we choose "JOSTON "?
1. We enhance the reliability of product's quality and working life .
2. We decrease the consumption cost of the product in the ruuning.
3. We improve research personnel's ability to deliver a creative design;
4. We use leading technologies in our product development and innovation, and thereby increase the competitive advantage of products.
7.Do you supply installation equipment in oversea?
Yes, if need, we can send our engineer to your plant to help you do installation and commission.
8.How can we know the order production status ?
We will arrange the person to take photo or video during manufacturing in every week to make you to know the production status.When goods are finished,we will take detailed photos or video for your checking ,after approve ,then we will arrange shipment .also you can arrange FAT in our plant when the goods is ready here
9.what is kind service do you offer before making order ?
1.according to your company URS ,we will make the design drawing accoridingly.
2.after your company approved drawing ,we will make quotation.
3. final we make agreement on payment terms ,delivery time ,package ,shipment etc.
10.how about your company after-sale serivce ?
1. We provide long-term after-sale service.
2. we can do installation and commission for the equipment in your plant if necessary .
3. Meanwhile, you can call or e-mail us to consult on any relevant question since we have a special line for after-sale service. Alternatively, you can communicate on-line with us to solve any problem.
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