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Your Location: Home >> News >> Technical support >> How to save the lyophilization cost of vacuum freeze dryer production operation

How to save the lyophilization cost of vacuum freeze dryer production operation

Release Date: 2019/12/20 17:29:30 .
Browse: 110

How to save the lyophilization cost of vacuum freeze dryer production operation
Although the added value of FD freeze-dried products is better than traditional dry products, its freeze-drying costs are relatively high. Freeze-drying costs include raw materials, staff salaries, and equipment operation costs. Here, Shanghai Tianfeng manufacturers discuss with you how to save the freeze-drying cost of vacuum freeze-dryer production and operation.
 There are three main factors that affect the production and operation costs of vacuum freeze dryers (hereinafter referred to as freeze dryers):
1. The influence from materials, such as eutectic point, thermal sensitivity, geometric size or thickness, etc., will have a large impact on the required drying time, and the operating cost will have a greater impact;
2. The influence of the adopted process route, such as the determination and grasp of the final freezing temperature, freezing rate, heating temperature, heating rate and time of the material, will affect the drying speed and operating cost.
3. The effect of the lyophilizer itself. The performance, limit parameter index, comprehensive capacity, energy utilization rate, operating stability, and ease of operation of the freeze dryer will have an impact on the drying efficiency and operating cost, and even seriously affect it.
的 The main ways to reduce the cost of equipment production and operation:
1. The eutectic point of materials with relatively simple components is relatively high. For example, the freezing temperature of vegetables is only about -15 ° C, the freezing time is short, the corresponding heating time is short, the energy consumption is relatively small, and the operating cost is low. And the composition is complicated, the eutectic point of materials containing organic or inorganic components such as salt, sugar, fat, amino acid, solvent, etc. is lower, the lower the freezing temperature, the longer the freezing time, the longer the corresponding heating time, and the higher the running cost.
2. Some biological products such as fungi, vaccines and other materials are very sensitive to heat, the heating temperature should not be too high (-15 ° C ~ 30 ° C), it is difficult to absorb heat, so it takes a long time to dry, and the running cost will be high. And materials with low thermal sensitivity (such as ordinary food) can be heated at a high temperature (75 ℃ ~ 100 ℃), the drying time will be greatly shortened, and the running cost will be very low.
3. Under the same weight, the smaller the geometric size, the larger the ice surface area of ​​the thin and loose material, the more conducive to sublimation, and the shorter the drying time. If the larger pieces of material are cut or broken into smaller pieces, the sublimation drying speed can be greatly improved, and the running cost can be reduced.
4. Thinning the product loading thickness, properly increasing the drying shelf area under the condition that the loading amount and equipment power consumption are unchanged, can improve the heat transfer capacity of the drying shelf, shorten the freezing and heating drying time, and reduce operating costs. However, equipment investment will increase slightly.
The choice of process route will also affect the drying speed and operating cost:
The quality performance of different freeze dryers varies widely. The performance related to the drying rate is mainly the cold trap temperature. The pressure difference between the drying box and the cold trap is determined by the temperature difference between the material in the drying box and the condenser. The larger the temperature difference, the greater the pressure difference, the faster the water vapor flows from the drying box to the condenser, and the shorter the drying time, so the temperature of the cold trap is an important factor affecting the operating cost. However, obtaining a lower cold trap temperature at the cost of higher energy consumption will still increase operating costs, so energy consumption indicators are also important. In addition, the change in vacuum and heat transfer capacity of the lyophilizer also affects the operating cost to a certain extent.
Freeze dryer
5. Controlling the pre-freezing speed results in ice crystal structures that are conducive to sublimation. The pre-freezing speed is too fast, the ice grains are small, the dried layer has fine pores, and the resistance of water molecules to flow through the dried layer is large, which affects the drying speed. Properly reduce the pre-freezing speed to make the ice grains coarse and the pores of the dried layer large, which will help the water vapor flow and increase the drying speed, but the premise is to ensure product quality.
6. Control the pre-freezing temperature The pre-freezing temperature should be controlled to an appropriate temperature below the eutectic point of the product. Too low a temperature will waste the cooling time for exceeding the temperature and the heating time for returning.
7. Control the heating temperature. The initial heating temperature should not be too high. The outer ice surface of the product can easily be melted by heat. The heating temperature is slowly performed from low to high. After the initial heating stage, the cold trap capacity is allowed and the product temperature does not exceed the co-melting point. The heating temperature can be increased as soon as possible to shorten the running time in the case of insufficient heating. Different products have different maximum allowable heating temperatures. The higher the maximum allowable temperature, the higher the heating temperature and the faster the drying speed.
8. Control of the residual moisture content of the product The residual moisture content of the product should be appropriate, too low will prolong the drying time, and too high will not be conducive to long-term storage of the product.
9. In the middle and late stages of drying, as the thickness of the dried layer of the product increases, it is like adding a thermal insulation layer to make the surface of the ice layer more difficult to heat. The main method of heating the ice layer of the product, increasing the heat transfer is an effective method to accelerate the drying speed.
10. Decrease the condenser temperature, because a large amount of water molecules from the drying box are "captured" by the condenser to form a frost layer on the surface of the condenser. The temperature difference is formed. The thicker the frost (generally 10 ~ 50mm), the larger the temperature difference (10 ~ 30 ℃). In this way, as the thickness of the frost increases, the surface temperature of the frost layer gradually rises, and even close to the temperature of the product's ice layer, the pressure also gradually increases, causing the water vapor pressure difference between the lyophilizer and the condenser to gradually decrease, and the drying rate to gradually decrease, or even Stop frosting and the product will melt. Therefore, reducing the temperature of the condenser as much as possible will help ensure an effective temperature and pressure difference between the drying box and the condenser. Generally, the temperature of the condenser is in the range of -40 ° C to -50 ° C. Reducing the temperature of the condenser such as -60 ° C to -70 ° C or even lower will be limited by the cost. However, for products with a lower eutectic point, such as below -30 ° C, a freeze dryer equipment with a condenser temperature of -60 ° C to -70 ° C or even lower should be selected.

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