Freeze Dryers

FD500 Continuous

The FD500 continuous is a modularised solution for full-scale freeze-drying factories. With all elements being delivered as plug-and-play it is easy to upscale or downscale as needed.

The FD500 Continuous freeze-drying system represents the next generation of freeze dryer factories. The modularized, optimised and perfected FD500 standard module is prepared for the automatic loading and unloading of trays.

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

Applications

The FD500 Continuous freeze-drying system is designed for the drying of nutraceuticals and 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

  • Up to 20x FD500 units, with condenser chamber below drying chamber and automated double doors (opposite each other as a pass-through unit)
  • Vacuum pump system with roots and a rotary vane pump
  • Refrigeration system
  • Control system with PLC incl. touch screen and data logging
  • The stainless steel support structure and maintenance platform for 1-level-layout with condenser chamber below drying chamber
  • FAT, SAT and CE documentation

Options

  • CIP return equipment
  • Clean-Factory-System for loading/unloading robot system (sealed hygienic and CIP-able enclosure wagons)
  • cGMP software and documentation package
  • Modularized fully automatic tray filling system
  • Modularized fully automatic tray emptying system

Other versions

  • The layout of dryers according to customer facility, e.g. in 2 rows with only 1 loading/unloading 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
Technical data Basic system with 5 x FD500 units
Total tray area 112,5 m2
Number of active trays 200
Input/feed capacity 2.500 kg/cycle (density 0,5 g cm3)
Total cooling coil capacity 2.000 kg H2O
Total maximum sublimation capacity 400 kg H2O/hour
Product contact steel parts AISI 316
Unit dimensions, WxDxH 19 x 6 x 4,1m