THE BASICS OF FREEZE DRYING

The Basics of Freeze Drying

The technology that drives our high end custom freeze dry machines begins with the knowledge of the process. Your process. 

Freeze Drying Basics

Freeze Drying Basics

There are 4 main stages in freeze drying and they all have an impact on the drying time.  These parts play an intricate roll on how long your process takes and which machine will best suit your needs.  A change to any of these can effect your process. 

The 4 stages of freeze drying

  • Pretreatment

    Any thing that you do to your product prior to freezing to add something to your product or aid in the freeze drying process is considered " pretreatment".   This can either increase or decrease the drying time.  For example, adding a sugar to your product may reduce its freezeing point.   Salts and alcohols can have this kind of impact as well.  


    For other applications,  such as when freezedrying pharmacueticals , API, probiotics etc, adding a cryo protectant may also reduce the freezing point making it critical to be able to have a machine that not only has a condenser that is below the freezing point of the product, but also have shelves that can maintain the shelf temp in negative numbers.  This cannot be done with electric heating shelves.  

  • Freezing

    The freezing, or nucleation of the product is incredibly important.  Hense the first word of the process.  Freeze. Flash freezing can be achieved with various methods.  Blast freezing, nitrogen pelletization etc, and will create smaller ice crystals which may slow down the freezedrying process, but yeild a better product.  Using a holding freezer that slowly freezes your product will create large ice crystals.   Larger ice crystals may sublimate faster, but may damage your product at the celluar level by piercing the cellular wall.  smaller ice crystals wont, but take longer to freeze dry.  Flash freezing, nitrogen pellitization will produce a quickly frozen product, and also small ice crystal size.  Allowing product to Freeze overnight in a walk in freezer may create larger ice crystals , but you may leech out vitamins, , destroy proteins, or loose your critical ingedients to your product.  

  • Primary Drying

    During this phase the majority of the water is sublimed out of the product.   Up to 90 , 95%.  it is critical to make sure the sublimation front of the product stays below either the Eutecti point, or the glass transition event.  this is why it is critical to use machines that offer precise control.  electric heaters dont offer this.  Be cautious when learning about your process if new, otherwise you could be stuck with an expensive machine that cant freeze dry your product, or takes much longer.  

  • Secondary Drying

    During this phase, the remaining 5% of the bound water must be removed, through desorption.  it is common to try to enter this phase too soon, this is when you see collapse on the prodeuct, which technically, you are boiling water off the productl, not sublimation.  this is vacuum drying.  check out our section on how to avoid this.  

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the main components on a freeze dryer

A freeze dryer has 5 main components:

  • the drying chamber
  • the refrigeration
  • the cooling and heating shelves
  • the vacuum pump
  • control  and monitoring systems
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  • The Drying Chamber

    Any thing that you do to your product prior to freezing to add something to your product or aid in the freeze drying process is considered " pretreatment".   This can either increase or decrease the drying time.  For example, adding a sugar to your product may reduce its freezeing point.   Salts and alcohols can have this kind of impact as well.  


    For other applications,  such as when freezedrying pharmacueticals , API, probiotics etc, adding a cryo protectant may also reduce the freezing point making it critical to be able to have a machine that not only has a condenser that is below the freezing point of the product, but also have shelves that can maintain the shelf temp in negative numbers.  This cannot be done with electric heating shelves.  

  • Refrigeration

    The freezing, or nucleation of the product is incredibly important.  Hense the first word of the process.  Freeze. Flash freezing can be achieved with various methods.  Blast freezing, nitrogen pelletization etc, and will create smaller ice crystals which may slow down the freezedrying process, but yeild a better product.  Using a holding freezer that slowly freezes your product will create large ice crystals.   Larger ice crystals may sublimate faster, but may damage your product at the celluar level by piercing the cellular wall.  smaller ice crystals wont, but take longer to freeze dry.  Flash freezing, nitrogen pellitization will produce a quickly frozen product, and also small ice crystal size.  Allowing product to Freeze overnight in a walk in freezer may create larger ice crystals , but you may leech out vitamins, , destroy proteins, or loose your critical ingedients to your product.  

  • The importance of cooling and heating shelves

    During this phase the majority of the water is sublimed out of the product.   Up to 90 , 95%.  it is critical to make sure the sublimation front of the product stays below either the Eutecti point, or the glass transition event.  this is why it is critical to use machines that offer precise control.  electric heaters dont offer this.  Be cautious when learning about your process if new, otherwise you could be stuck with an expensive machine that cant freeze dry your product, or takes much longer.  

  • Vacuum pump setup

    During this phase, the remaining 5% of the bound water must be removed, through desorption.  it is common to try to enter this phase too soon, this is when you see collapse on the prodeuct, which technically, you are boiling water off the productl, not sublimation.  this is vacuum drying.  check out our section on how to avoid this.  

  • Control and monitoring systems

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find the right freeze dryer for you

"Donec ullamcorper nulla non metus auctor fringilla. Cras justo odio, dapibus ac facilisis in, egestas eget quam."


- Client

Freeze Dried Rasberries

freeze drying vs vacuum Drying

 Whether it is helping with your process, reconditioning or repurposing your freeze dryer, Scaling up to handle more product, we will help you make the right decision to custom fit your company's needs with a turnkey lyophilization solution. This is the US Freeze Dry way. 

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"Donec ullamcorper nulla non metus auctor fringilla. Cras justo odio, dapibus ac facilisis in, egestas eget quam."


- Client

Shelves

There are different mediums for heating shelves.  There are advantages of each.  So long as they are engineered properly. 


Make sure you are paired with the right type for your application.

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