The Basics of Freeze Drying
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.
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.
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.
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.
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.
Pretreatment can change your products chemical makeup Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 1Nucleation and its importance in the Drying process Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 2Primary drying. Using the correct machine Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 3secondary drying, why ramping too quickly may be ruining your product Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 4wrong dryer equals money out the window Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Linkwhat is the importance of temperature control during drying? Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Linkbulk flow vs diffusive flow which do you want? Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
New List Item Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item LinkA freeze dryer has 5 main components:
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.
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.
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.
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.
is the shape of my freeze dryer important? Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 1ability to close off chamber from condenser, sterilize if needed. ability to determine water in chamber. compare other companies that use the tech to show water going through the vacuum pumps, that isnt freeze drying. not posible to do this unless the condenser is inbetween the product and vacuum pumps.
how much of a role does refrigeration play? Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 3do i need shelves that heat and cool? Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Link List Item 4the importance of the vacuum system. Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Linkwhat type of control do i need on my equipment? Write a description for this list item and include information that will interest site visitors. For example, you may want to describe a team member's experience, what makes a product special, or a unique service that you offer.
Item Linkto be or not to be..... When it comes to the method to heat your shelves is very important
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.
There are different mediums for heating shelves. There are advantages of each. So long as they are engineered properly.
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