The SD Freeze Drying factory setup represents the next generation of freeze-drying factories. The modularized, optimised and perfected FD500 standard module is prepared for the automatic loading and unloading of trays. With all elements being delivered as plug-and-play it is easy to upscale or downscale as needed.
The modules can be combined in a desired and suitable layout to reach the needed output capacity. Clean and hygienic: The racks are transported to and from the drying chambers in a sealed enclosure (the Clean-Factory -System) – all equipment is designed based on the highest hygienic standards and is fully CIP-able.
Increasing capacity
- Cost savings and production optimisation
- Reduced utility system investments
- Reduced installation costs, documentation and commissioning due to comprehensive standardisation of modules
- Optimised footprint
- Reduced manual operations
- Maintenance of the individual dryers during production
- Standardised control system handling and documentation of all batches better
Scaling the production
- No scalability risk due to modularization
- Flexibility and simple capacity expansion – expansions are made fast and inexpensive by adding standard FD500 module(s). Each module will arrive at the customer’s site in a 20’ container for plug-and-play installation
- The loading and unloading robot, as well as the control system, are pre-designed for expansions
Hygiene
- Product integrity is secured via Clean-Factory-System
- Loading and unloading can be easily positioned in separate cleanrooms if a product, process, and production setup requires a separation
- All equipment, instruments, design, and solutions are of the highest sanitary design
- No silicone oil or water for heating
- No manual intervention
- No cross-contamination
Factory setup
Applications
The factory can be designed for the drying of food, beverage, dairy and nutraceutical applications such as dietary supplements e.g. probiotic bacteria, colostrum, enzymes, and allergen extracts.
Benefits of the FD500:
Fast and low-cost capacity increase:
- Capacity can be increased by adding standard FD500 freeze-drying units to the system
No risk when up-scaling production:
- Using a standard FD500 dryer unit and known recipe parameters results in identical output products from all chambers
Production flexibility:
- Different products can be dried simultaneously
Reduced utility investment costs:
- E.g. size of the CIP unit is minimised since only one drying unit is CIP’ed at a time
Manual operations are reduced:
- The fully automatic system reduces the need for manual labour and OPEX
Foot-print flexibility:
- The layout of the freeze-drying units, emptying station etc. is tailored to customer needs, allowing large systems to be fitted into existing buildings. Units can even be in 2 levels
Clean and hygienic:
- The racks are transported to and from the drying chambers in a sealed enclosure (the Clean-Factory-System) – all equipment is designed based on the highest hygienic standards
Easy maintenance:
- One unit can be shut down for maintenance while the remaining units are in use
For GMP applications:
- Lower qualifying costs – the qualifying documentation for the first unit can be used as a template for the subsequent units
Basic System
- Fits in a 20’ container
- Stainless steel drying chamber
- Stainless steel condenser chamber
- Stainless steel condenser coil
- Complete refrigeration system
- Vacuum pump system with roots and dry screw pump
- Pressure sensors (high and low)
- Electrical heating shelves/plates
- Natural anodized aluminium product trays
- Touch screen control panel with PLC
- Data logging
- Defrost of condenser
- FAT, SAT and CE-documentation
- Hygienic design prepared for CIP
- Design prepared for robot automation
- Isolation valve
Options
- CIP equipment for both chambers
- CIP return equipment
- Nitrogen purging
- Pre-cooling of drying chamber
- Sterile filters for in-/outlet flows
- Manual wire stainless steel sheeted thermocouples for product temperature measurement
- Double pressure sensor set
- GMP software and documentation package
Other versions
- SIP-able + equipment
- Silicone heating/cooling shelves/plates including system
Benefits of the FD500:
Fast and low-cost capacity increase:
- Capacity can be increased by adding standard FD500 freeze-drying units to the system
No risk when up-scaling production:
- Using a standard FD500 dryer unit and known recipe parameters results in identical output products from all chambers
Production flexibility:
- Different products can be dried simultaneously
Reduced utility investment costs:
- E.g. size of the CIP unit is minimised since only one drying unit is CIP’ed at a time
Manual operations are reduced:
- The fully automatic system reduces the need for manual labour and OPEX
Foot-print flexibility:
- The layout of the freeze-drying units, emptying station etc. is tailored to customer needs, allowing large systems to be fitted into existing buildings. Units can even be in 2 levels
Clean and hygienic:
- The racks are transported to and from the drying chambers in a sealed enclosure (the Clean-Factory-System) – all equipment is designed based on the highest hygienic standards
Easy maintenance:
- One unit can be shut down for maintenance while the remaining units are in use
For GMP applications:
- Lower qualifying costs – the qualifying documentation for the first unit can be used as a template for the subsequent units
This factory example consists of 5 FD500 units.
| Technical data | Basic system with 5 x FD500 units |
| Total tray area | 135 m2 |
| Number of active trays | 240 |
| Input/feed capacity | 2.500 kg/cycle (density 0,5 g cm3) |
| Total cooling coil capacity | 4.000 kg H2O |
| Total maximum sublimation capacity | 400 kg H2O/hour |
| Unit dimensions, WxDxH | 19 x 6 x 4,1m |
