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 up-scale or down scale 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 un-loading 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 un-loading robot as well as the control system are pre-designed for expansions

Hygiene

  • Product integrity is secured via Clean-Factory-System
  • Loading and un-loading can be easily positioned in separate cleanrooms if 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 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 pass-through unit)
  • Vacuum pump system with a roots and a rotary vane pump
  • Refrigeration system
  • Control system with PLC incl. touch screen and data logging
  • 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/un-loading 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

  • Layout of dryers according to customer facility, e.g. in 2 rows with only 1 loading/un-loading 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