Deep 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
A Deep Freeze Dryer is a device used to dry substances at low temperatures.
Its working principle mainly includes the following key steps:
1.Cryogenic freezing:The substance is first placed in the device and frozen at a low temperature of -60 ° C to -120 ° C.
2.Temperature control and capture:In a vacuum environment,the equipment removes organic solvents,complex solvents,and water in substances through temperature control and capture steps.
3.Retention of material properties:This method can avoid the organic solvent products in the substance,complex solvents,biological products can not be frozen into solid,while retaining the original molecular structure of the substance,active substances,morphology and properties are basically unchanged.
(View other types:Laboratory Freeze Dryer;Pilot freeze dryer;Industrial Freeze Dryer)
Specifications Table
Method of temperature adjustment
Temperature adjustment procedure
To open the device:
First, make sure the device is turned on and in standby.
Turn on the power switch of the device and wait until the device starts and runs stably.
Set temperature:
Most devices are equipped with a temperature controller, on which the user can set the desired temperature through a knob, key or touch screen.
According to the characteristics of the material and drying requirements, set the appropriate freezing temperature and drying temperature. In general, the freezing temperature should be maintained between -30 ° C and -40 ° C to ensure that the moisture in the material can be fully frozen into ice crystals; The drying temperature is usually maintained between -20 ° C and -30 ° C, which helps to sublimate the ice crystals, while avoiding overheating of the material resulting in a decline in quality.
Observation and adjustment:
During the operation of the equipment, constantly observe the temperature change to ensure that the temperature is stable near the set value.
If it is found that the temperature deviates greatly from the set value, or cannot reach the required temperature range, adjust the temperature controller in time, or check whether the cooling system and heating system of the equipment are working normally.
Precautions
Temperature control accuracy:
Deep freeze dryers need to have high temperature control accuracy to ensure the stability of the drying process and product quality. Therefore, when setting the temperature, it should be as accurate as possible to one or two decimal places.
Temperature fluctuation range:
During the drying process, the temperature may fluctuate due to a variety of factors. In order to ensure product quality, a reasonable temperature fluctuation range should be set, and the impact of temperature fluctuations on the drying process should be minimized.
Cooling and heating system:
Its cooling and heating systems are key components in controlling temperature. When adjusting the temperature, it should be ensured that the two systems are working properly and are able to meet the required temperature range. If the system is faulty or abnormal, contact professional personnel for repair and maintenance.
Material characteristics:
Different materials may have different temperature requirements. Therefore, when setting the temperature, the characteristics and drying needs of the material should be fully considered to ensure that the drying process can proceed smoothly and achieve the desired effect.
Safe operation:
When adjusting the temperature, you should follow the safety operation procedures to avoid electric shock, scalding and other safety accidents. At the same time, ensure that the device is properly grounded to prevent security risks such as static electricit
Application
Technological Industry
In chemical synthesis,products are often lyophilized to make them more stable,or easier to dissolve in water for subsequent use.In bio separations,freeze-drying can be used also as a late- stage purification procedure,because it can effectively remove solvents.Also it is capable of concentrating substances with low molecular weights that are too small to be removed by a filtration membrane.
Pharmaceutical Industry and Biotechnology
Pharmaceutical companies often use freeze-drying to increase the shelf life of products,such as vaccines and other injectable.By removing the water from the material and sealing the material in a vial,the material can be easily stored,shipped and later reconstituted to its original form for injection.
Food Industry
Freeze-drying is used to preserve food and make it very light weight.The process has been popularized in the forms of freeze- dried ice cream;an example of astronaut food.The coffee is often dried by vaporization in a hot air flow,or by projection on hot metallic plates.Freeze-dried fruit is used in some breakfast cereal.Culinary herbs are also freeze-dried,although air-dried herbs are far more common and less expensive.
Market size and growth trend
Global market size
According to relevant market research reports,the global freeze-drying equipment market is growing year by year.For example,reports predict that the global freeze-drying market will reach $1.206 billion (about 8 billion yuan) by 2029,showing strong growth momentum.
Another report pointed out that the global freeze-drying equipment market size reached 16.881 billion yuan in 2023,and is expected to grow to 27.654 billion yuan by 2029,with an annual compound growth rate of 8.23%.
Chinese market size
China's freeze-drying equipment market is also expanding year by year.In 2023,China's freeze-drying equipment market has reached 4.951 billion yuan,and is expected to continue to maintain rapid growth in the next few years.
In the Chinese market,freeze-drying machines for food as an important part of the market has also achieved significant growth,mainly due to the increasing demand of consumers for high-quality,convenient and nutrient-rich food,as well as the increasing attention of the food processing industry to freeze-drying technology.
Competitive pattern
Market competitors
The global deep freeze dryer market shows a diversified competitive pattern,and the main manufacturers are distributed in Europe,the United States and Asia.These enterprises in technology research and development,product quality,after-sales service and other aspects of fierce competition to compete for market share.
Market concentration
The world's top five freeze-drying machine manufacturers have a market share of about 43.0%,showing the characteristics of high market concentration.In the Chinese market,with the intensification of industry competition,market concentration is also expected to further increase.
Energy consumption
General energy consumption
The energy consumption of the equipment is closely related to the model, specification, working condition and operating environment of the equipment.Typically,the energy consumption of such devices ranges from several kilowatts to tens of kilowatts per hour.The specific energy consumption depends on the refrigeration capacity of the equipment,the capacity of compressed air,the working environment temperature,the water content of the material and the working conditions and other factors.
Factors affecting energy consumption
Equipment specifications and models:Different specifications and models of deep freeze dryers have different energy consumption levels.In general,the larger the equipment,the stronger the cooling capacity,the higher its energy consumption.
Operating ambient temperature:The ambient temperature has a great influence on the energy consumption of the equipment.When the ambient temperature is higher,the device needs to consume more energy to maintain the required low temperature environment.
Water content of the material:The initial water content of the material also affects the energy consumption of the equipment.Materials with high water content require a longer condensation and drying process,which increases the energy consumption of the equipment.
Working conditions:such as the running time of the equipment,working pressure,etc.,will also affect its energy consumption.The energy consumption of the equipment is usually higher in long continuous operation or high pressure working conditions.
Ways to reduce energy consumption
Optimize equipment selection:Select the right equipment specifications and models according to actual requirements to avoid energy waste caused by too large or too small equipment.
Improve the working environment:Reduce the working environment temperature and improve the heat dissipation efficiency of the device to reduce the energy consumption during the running of the device.
Control material moisture content:The material is pretreated before entering the unit to reduce its moisture content, thereby reducing the drying time and energy consumption of the unit.
Regular maintenance:Perform regular maintenance and maintenance on the equipment to ensure that it is in good working condition and reduce energy consumption caused by equipment failure or performance degradation.
Case analysis
Taking a certain type of equipment as an example, its energy consumption in practical applications may be as follows:Under standard operating conditions,the device consumes about 8 KWH per hour (or more,depending on the factors mentioned above).If the equipment runs continuously for 24 hours,the daily power consumption can reach 192 KWH or more.Therefore, when using the equipment, its energy consumption should be fully considered, and corresponding energy-saving measures should be taken to reduce operating costs.
Programmable control system
The basic composition of programmable control system
The programmable control system of deep freeze dryer is mainly composed of hardware and software.
Hardware part:
Programmable controller (PLC) : As the core of the control system, PLC is responsible for receiving sensor signals, executing preset programs, controlling actuators and other tasks. It usually has a modular design for easy expansion and upgrading.
Sensor: Used to monitor the temperature, pressure, humidity and other parameters of the material or equipment in real time, and transmit the data to the PLC for processing.
Actuator: According to the PLC instructions, adjust the heating/cooling elements, vacuum pumps, valves and other equipment operating state, to achieve accurate control of the material handling process.
Human Machine interface (HMI) : provides an intuitive operation interface for operators to monitor equipment status, adjust parameters and view alarm information.
Software part:
Control program: According to the material characteristics and processing requirements, the preset control program is run in the PLC to achieve accurate control of the equipment parameters.
Monitoring software: used to monitor equipment status in real time, record operating data and alarm information, and provide data analysis and report generation functions.
The functional characteristics of programmable control system
Through the preset program and algorithm, the programmable control system can realize the precise control of the machine parameters, and the whole drying process can be completed without manual intervention.
The system adopts advanced control algorithm and sensor technology, which can monitor and adjust the temperature, pressure and other parameters inside the equipment in real time to ensure that the material is dried under the best conditions.
Users can customize control procedures and parameter Settings according to material characteristics and processing requirements to meet different production needs.
Through the human-machine interface and network technology, the operator can remotely monitor the operating status and parameter changes of the equipment, and discover and deal with abnormal situations in a timely manner.
The system has fault alarm and diagnosis functions, which can monitor the operating status of the equipment in real time, and immediately send an alarm signal and provide fault diagnosis information once a fault or abnormal situation is found.
Application of programmable control system
In this machine, the programmable control system is widely used in the following aspects:
Temperature control
Precise control of the material temperature is achieved by precisely controlling the output power and working time of the heating/cooling element. This helps to ensure that the material is dried within the optimal temperature range, avoiding the impact of overheating or undercooling on the quality of the material.
01
Pressure control
By adjusting the operating state of the vacuum pump and the opening of the valve, the control system can accurately control the pressure inside the equipment. This helps to speed up the sublimation process of water and improve drying efficiency.
02
Stage control
According to the material characteristics and processing requirements, the programmable control system can divide the entire drying process into several stages, and adopt different control strategies and parameter Settings at each stage. This helps to ensure that the material is treated optimally at every stage.
03
Data recording and analysis
The system can record the operating status and parameter changes of the equipment in real time, and provide data analysis and report generation functions. This helps operators understand the performance and productivity of the equipment, and identify and resolve problems in a timely manner.
04
Advantages and challenges of programmable control system
Advantages
Increased production efficiency
Through automated control and precision control, the programmable control system can significantly improve the production efficiency of the equipment.
Improve product quality
Precise temperature and pressure control helps ensure that materials are dried under optimal conditions, thereby improving product quality.
Reduce power consumption
By optimizing control policies and parameter Settings, the system can reduce power consumption and operating costs.
Challenge
Technical complexity
The design and debugging of programmable control systems require a high level of technology and have certain requirements for the professional skills of operators.
Device compatibility
Different brands and models of machines may have different control systems and interface standards, which can lead to challenges in terms of compatibility and versatility for programmable control systems.
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