Freeze Dryers

FD500

The FD500 represents the next generation of freeze dryer solutions for the process industry – a modularizing freeze dryer. It offers high capacity, optimised energy efficiency and is virtually maintenance-free.

The FD500 offers the highest hygienic standard in the industry and its flexibility enables it to be used in many setups and applications. The FD500 dryer can optionally be delivered with CIP spray nozzles installed for full coverage of CIP- liquid.

FD500 is a hygienic bulk freeze dryer with an external condenser that can be isolated from the drying chamber. Heating for sublimation is supplied by stainless steel PTFE-coated electrical heating elements. The heating elements secure a uniform temperature gradient and pressure across the entire tray surface area. This construction offers the highest level of hygienic design and eliminates the risk of silicone oil and heating water leakages within the chamber as well as reduced maintenance costs.

The design is optimised for upscaling and easy maintenance. The FD500 dryer features CIP spray nozzles which are installed for full coverage of the CIP liquid. It is manufactured from stainless steel (AISI 316), and all surfaces wetted by CIP-liquid are documented with either 3.1, FDA and/or FCM certificate.

Each module is designed for a complete assembly and function test in the SD Freeze Drying factory and will be shipped in a 20’ container ready for installation – plug-and-play.

Applications

The FD500 freeze dryer is designed for drying nutraceuticals and dietary supplements e.g.:

  • Probiotic bacteria
  • Colostrum
  • Enzymes
  • Allergen extracts

While also working within the food industry for applications such as:

  • Fruits and vegetables
  • Whole meals
  • Instant coffee

Benefits of the FD500

Scalability:

  • Optimised flow, pressure and heat input secure a smooth up-scaling from FD30 pilot size to FD500 full scale

Reduced utility investment and maintenance:

  • For e.g. the heating for sublimation is done by electric heating elements, eliminating the need for a water or silicone heating system

Improved product integrity:

  • The risk of contamination by leaking water or silicone oil is eliminated using electrical heating elements for sublimation

Improved cleanability:

  • Isolated external condenser chamber and PTFE coated heating elements combined with a state-of-the-art general hygienic design, means that the cleanability of the freeze dryer is very high

Skid-mounted:

  • The freeze dryer is delivered as a skid-mounted assembly in a standard container – tested and ready for installation. This minimises the need for on-site fabrication and reduces the erection time

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
  • Wireless product temperature probes
  • Touch screen control panel with PLC
  • Data logging
  • Stainless steel frame and cladding
  • Defrost of condenser
  • FAT, SAT and CE-documentation
  • A hygienic design prepared for CIP
  • A 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-/out-let flows
  • Manual wire stainless steel sheeted thermocouples for product temperature measurement
  • A double pressure sensor set
  • cGMP software and documentation package

Other versions

  • SIP-able + equipment
  • Silicone heating/cooling shelves/plates including system

Benefits of the FD500

Scalability:

  • Optimised flow, pressure and heat input secure a smooth up-scaling from FD30 pilot size to FD500 full scale

Reduced utility investment and maintenance:

  • For e.g. the heating for sublimation is done by electric heating elements, eliminating the need for a water or silicone heating system

Improved product integrity:

  • The risk of contamination by leaking water or silicone oil is eliminated using electrical heating elements for sublimation

Improved cleanability:

  • Isolated external condenser chamber and PTFE coated heating elements combined with a state-of-the-art general hygienic design, means that the cleanability of the freeze dryer is very high

Skid-mounted:

  • The freeze dryer is delivered as a skid-mounted assembly in a standard container – tested and ready for installation. This minimises the need for on-site fabrication and reduces the erection time
Total tray area 27 m2
Number of trays 48
Input/feed capacity 1.200 kg
Cooling coil capacity +500 kg H2O
Maximum sublimation capacity 80 kg H2O/hour
Product contact steel parts AISI 316
Unit dimensions, W x D x H 2,3 x 5,5 x 2,3 m

FD500 data sheet

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