Compact Freeze Dryer
(a)10 series
Lab Scales Desktop(Freeze-dried material 1.5-2KG)
(b)12 series
Lab Scales Vertical(Freeze-dried material 2KG)
(c)18 series
Scientific Research Scales(Freeze-dried material 3KG)
2.Pilot Freeze Dryer:
0.2m²/0.3m²/0.5m²/1m²/2m²/---Pilot Scales(Freeze-dried material 3KG-20KG)
3.Industrial Freeze Dryer:
5㎡/10㎡/20㎡/30㎡/50㎡/100㎡/200㎡/300㎡(Freeze-dried Weight 5T~60T)
4.Customization: set up the specifications you need
(a)Freeze-dried Area
(b)Freeze-dried Weight
(c)Freeze-dried Material
(d)Interlayer Quantity/Size
(e)Cold Trap Temperature
Description
Technical Parameters
TheCompact Freeze Dryer is a specialized equipment for removing water from substances. It is based on vacuum freeze-drying technology and is widely used in fields where the original structure and activity of substances need to be maintained. By first freezing the substance below its triple phase point and then sublimating it under vacuum, water is effectively removed while maintaining the original properties and activity of the substance. Based on the three-state change of water, especially the direct conversion between solid (ice) and gas (water vapor), i.e. sublimation principle. Substances in the frozen state, through the vacuum environment to make ice sublimation directly into water vapor, so as to achieve the purpose of drying.The installation and environmental requirements of this equipment involve many aspects, including location selection, space requirements, power supply requirements, floor requirements, temperature requirements, humidity requirements, air quality requirements, cleanliness and hygiene, etc. Only by meeting these requirements can the stable operation of the equipment be guaranteed and its service life be prolonged.
We provide Compact Freeze Dryer, please refer to the following website for detailed specifications and product information.
Product: https://www.achievechem.com/freeze-dryer/laboratory-freeze-dryer.html
Product Structure & Model
10 Series Laboratory Freeze Dryer
12 Series Laboratory Freeze Dryer
18 Series Laboratory Freeze Dryer
Products Development
Maintenance cycle
Major maintenance cycle
Major maintenance is recommended once a year. Major maintenance is mainly to carry out comprehensive inspection, repair and replacement of parts of the equipment to ensure the overall performance of the equipment. This includes, but is not limited to:
Conduct a comprehensive inspection of the electrical system, including the measurement of voltage, current, insulation resistance and other parameters, as well as the aging and damage inspection of electrical components.
A comprehensive inspection of the refrigeration system, including the measurement of refrigeration temperature, refrigerant pressure and other parameters, as well as the compressor, condenser, evaporator and other parts of the operating status check.
A comprehensive inspection of the vacuum system, including the measurement of vacuum degree, leakage rate and other parameters, as well as the operation status of the vacuum pump.
Replace wearing parts, such as seals, filters, vacuum pump oil, etc.
Small maintenance cycle
Minor maintenance is recommended every three months. Minor maintenance is the routine inspection, cleaning and adjustment of the equipment to maintain the good condition of the equipment. This includes, but is not limited to:
Clean the surface and interior of the equipment, especially the condenser and evaporator, to ensure that the surface is free of dirt to maintain a good heat dissipation effect.
Check and clean the automatic drain and manual drain valves to ensure smooth drainage.
Check and tighten all screws, bolts, and fixtures to ensure that the structure of the device is stable.
Check and clean all electrical connections to ensure good contact.
Daily maintenance
In addition to major and minor maintenance, daily maintenance is also required. This includes:
1) Before starting each time, it is necessary to routinely check whether all the stop valves (compressor suction and exhaust valves, liquid supply valves, hand valves, etc.) are open, and whether the reading of each pressure gauge, compressor oil level, cooling water pressure and temperature are normal.
2) After power supply, check whether the compressor automatically receives liquid, whether the oil pressure difference is reset, and the heater of the crankcase is heated.
3) After starting, pay attention to check the compressor running sound, refrigeration pipeline vibration, compressor vibration, liquid mirror flow, expansion valve frosting and compressor frosting.
4) Check the condition of lubricating grease regularly and replace as needed. The replacement cycle of lubricating oil is affected by the temperature of the compression end, and the lubricating oil should be checked once every 10,000 hours of continuous operation under normal circumstances.
Application advantages
Compact freeze dryers have demonstrated significant advantages in fields such as biomedicine, food processing, and scientific research experiments through optimized structural design and functional integration. The following is an analysis from dimensions such as technical characteristics, economic benefits, and operational convenience:
Space and Cost-effectiveness
It occupies a small area and is adaptable to flexible scenarios
The equipment volume is 40%-60% smaller than that of traditional models. The laboratory-grade model usually occupies an area of no more than 0.5 square meters and can be easily embedded in a laminar flow hood, fume hood or mobile workstation. It is suitable for laboratories, clinics or small production lines with limited space.
Case: A certain biological laboratory has compressed the freeze-drying area from an independent room to a standard laboratory bench by replacing it with compact equipment, increasing the space utilization rate by 70%.
Reduce the initial investment and operation and maintenance costs
Compact equipment adopts an integrated design, reducing the redundancy of components such as refrigeration systems and vacuum pumps, and the procurement cost is 30%-50% lower than that of industrial-grade models.
The energy consumption optimization is remarkable, with the energy consumption per batch reduced by 20% to 30%, and the long-term operating costs saved significantly.
Data comparison: After comparison, a certain food enterprise found that the annual power consumption of compact equipment (about 8,000 KWH) is only 67% of that of traditional models (12,000 KWH).
Technical Performance and Product Quality
The low-temperature control is precise and the activity retention rate is high
The pre-freezing temperature can reach -80℃, with a temperature fluctuation of ≤±0.5℃, ensuring that the molecular structure of heat-sensitive substances (such as proteins and probiotics) is not damaged.
The activity loss rate of the product after freeze-drying is ≤5%, and the rehydration rate is ≥95%, which is significantly better than that of hot air drying (activity loss rate of 30%-50%).
Application case: A certain vaccine research and development institution used a compact device to freeze-dry mRNA vaccines, with an activity retention rate of 98%. The efficacy after resolubility showed no significant difference from that of fresh samples.
The vacuum system is highly efficient, and the drying efficiency is improved
Equipped with a combination of rotary vane pump and Roots pump, the pumping speed can reach 300-500L/s, the ultimate vacuum is ≤3Pa, and the sublimation rate is 3-5 times higher than that of natural convection.
Shorten the drying cycle by 20% to 40%. For instance, a freeze-drying process that takes 48 hours to complete with traditional equipment can be finished within 24 to 30 hours with compact equipment.
Industry data: After the freeze-drying cycle in the pharmaceutical field was shortened, the single-batch production capacity increased by 33%, and the comprehensive utilization rate of equipment rose by 25%.
Convenience of operation and maintenance
Intelligent control lowers the operation threshold
Integrated with PLC or touch screen control system, it supports more than 10 pre-stored process curves. One-click start automatically completes the entire process of pre-freezing, sublimation and desorption.
It displays parameters such as temperature, vacuum degree and operating status in real time. When abnormalities occur, it automatically alarms and prompts solutions. Non-professionals can operate it after simple training.
User feedback: Students in a laboratory of a certain university stated that the compact equipment has an intuitive operation interface and can complete freeze-drying experiments on the first use, with an efficiency improvement of 50%.
Modular design, low maintenance cost
The core components such as the cold trap and vacuum pump adopt a quick-disassembly structure, reducing the maintenance time to one-third of that of traditional models.
Equipped with automatic defrosting and self-cleaning functions, it reduces manual intervention and lowers the annual maintenance cost of the equipment by 40%.
Case: A certain food processing plant reduced the equipment downtime from an average of 72 hours per year to 24 hours through modular design, and increased production efficiency by 67%.
Application Scenario Scalability
It is applicable to both scientific research and small-scale production
It supports a single-batch processing capacity of 0.5 to 5 kilograms, meeting the needs of small-scale, medium-scale and small-scale mass production in laboratories, and avoiding equipment idleness and waste.
Application field:
Biomedicine: Freeze-drying preservation of vaccines, antibodies and cell cultures.
Food processing: Preparation of high-end fruit and vegetable powder, coffee extract, and functional food raw materials.
Materials Science: Drying and shaping of nanomaterials and biosensors.
Mobility and emergency response capabilities
Some models are equipped with on-board power interfaces or lithium battery power supply, supporting immediate freeze-drying processing in scenarios such as field sampling and disaster relief.
Case: A certain environmental protection agency used compact equipment to freeze-dry water samples in field monitoring. The transportation loss rate was reduced from 30% to 5%, and the analysis accuracy was significantly improved.
Summary and selection suggestions
Compact freeze dryers, with their three core advantages of space optimization, performance improvement and operation simplification, have become the first choice for laboratories, small and medium-sized enterprises and special scenarios.
Key points for selection:
Pre-freezing temperature ≤-60℃, vacuum degree ≤5Pa, cold trap capacity ≥3L (laboratory grade).
Give priority to choosing intelligent models that support remote monitoring and data traceability.
Pay attention to the after-sales service network to ensure the timeliness of spare parts supply.
This equipment not only enhances production efficiency and ensures product quality, but also significantly reduces the overall cost. It is an important tool for promoting the popularization of freeze-drying technology.
Installation and environment requirements
Installation requirements
Location selection:
The compact freeze dryer should be installed in an indoor environment with good ventilation, dry, and no direct sunlight.
Do not install in a place with damp, dusty, corrosive or combustible gases to prevent equipment damage or affect the drying effect.
Space requirements:
Make sure there is enough space around the equipment for heat dissipation and servicing, it is usually recommended to leave a gap of at least 1.5 meters around the equipment.
If multiple devices need to be placed in the same room, pay attention to avoid mutual influence between devices and ensure that the heat dissipation ports are not relative.
Power requirements:
Connect a stable and reliable power supply to ensure that the voltage and frequency meet the equipment requirements.
The allowable fluctuation of the power supply voltage should be less than ±10%, and the leakage circuit breaker with appropriate capacity should be set up.
Ground requirements:
The device must be installed on a flat and stable ground to avoid unstable running or noise caused by tilt or unevenness.
Environmental requirements
Temperature requirements
The temperature of the installation environment should be kept in a suitable range, which is usually recommended to be controlled between 10 ° C and 35 ° C (it is also said to be 2 ° C to 45 ° C or 2 ° C to 38 ° C).
Keep the ambient temperature from being too high or too low to affect the cooling and drying performance of the device.
Humidity requirements
The humidity of the installation environment should be moderate to avoid short circuit of the internal appliances or rust of the shell.
Relative humidity is generally recommended to be controlled below 80%.
Air quality requirements
Avoid conductive dust, explosive gas, corrosive gas, and strong electromagnetic field interference in the installation environment.
In particular, avoid corrosive components (such as ammonia) in the air to prevent damage to the equipment.
Cleanliness and Hygiene
Keep the installation environment clean and hygienic, and regularly clean the dust and debris around the equipment.
Avoid installing the device in a place with a lot of wood chips and dust, such as next to the grinder, to prevent blocking the radiator.
Other precautions
Pretreatment filter
A pre-treatment filter is installed at the front of the freeze dryer to pre-treat the compressed air to remove oil, water and particle impurities.
This helps prevent pipe clogging and extends equipment life.
Drainage system
The automatic drain should be connected to the drain, and ensure that the height of the drain is not higher than the drain.
Clean the drainage system regularly to prevent blockage and pollution of the production environment.
Operation and maintenance
Strictly follow the equipment operation rules to avoid equipment damage or accidents caused by misoperations.
Regular maintenance and maintenance of the equipment, including cleaning, inspection, replacement of wearing parts, etc.
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