Tianfeng TF-FZG-50 Production-Scale Vacuum Freeze Dryer
| Brand | Tianfeng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Manufacturer |
| Product Category | Domestic |
| Model | FZG-50 |
| Instrument Type | Standard Shelf-Type Freeze Dryer |
| Application Scope | Production-Scale |
| Lyophilization Area | 50.31 m² |
| Ultimate Vacuum | ≤ 2.7 Pa |
| Condensate Capacity (24 h) | 800 kg |
| Cold Trap Temperature | ≤ −65 °C |
| Main Unit Dimensions | 9.1 × 2.5 × 3.6 m |
Overview
The Tianfeng TF-FZG-50 is a production-scale vacuum freeze dryer engineered for continuous, GMP-aligned lyophilization of heat-sensitive biological and food-grade materials. It operates on the fundamental principle of sublimation—removing water from frozen product under deep vacuum while maintaining material integrity, structural stability, and bioactivity. Unlike conventional thermal drying methods, freeze drying preserves volatile compounds, enzymatic activity, color, texture, and nutritional value—making it indispensable for high-value applications in functional foods (e.g., shan zha/hawthorn, edible fungi), herbal extracts, biopharmaceutical intermediates, pet nutrition, and instant beverage concentrates. Designed for industrial throughput, the TF-FZG-50 integrates a unified chamber–condenser architecture with front-chamber/rear-trap configuration, enabling efficient vapor migration, minimal pressure gradient loss, and reproducible batch uniformity across its 50.31 m² effective shelf area.
Key Features
- GMP-compliant construction: Freeze-drying chamber and shelves fabricated from electropolished AISI 304 stainless steel with mirror-finish interior surfaces; zero dead-leg design and fully drainable geometry to meet hygienic process requirements.
- Modular shelf system: Dual-tier configuration with (15 + 1) × 2 shelves; customizable shelf material options—high-thermal-conductivity anodized aluminum or seamless 304 stainless steel—both surface-treated for cleanability and thermal homogeneity.
- High-capacity cold trap: Stainless-steel coil condenser rated for ≤ −65 °C operating temperature and 800 kg/24 h ice capture capacity; available in monolithic or segmented configurations per user-defined maintenance access requirements.
- Robust refrigeration architecture: High-efficiency dual-stage cascade refrigeration system using premium imported compressors; rapid cooldown to −65 °C in ≤ 90 minutes from ambient, with stable shelf temperature control from −45 °C to +80 °C.
- Advanced vacuum management: Integrated ULVAC (Edwards/Airco equivalent) high-vacuum pump train with variable-speed drive and real-time pressure feedback; achieves ≤ 2.7 Pa ultimate vacuum with low oil carryover and long service intervals.
- Intelligent control platform: Omron CJ2M PLC paired with industrial IPC running proprietary lyo-control software; supports multi-step recipe programming, real-time parameter logging (shelf temp, chamber pressure, condenser temp, sublimation rate), and remote monitoring via Wi-Fi-enabled HMI.
Sample Compatibility & Compliance
The TF-FZG-50 accommodates heterogeneous sample loads—including bulk trays of sliced fruit (e.g., hawthorn), whole mushrooms, minced meat, seafood fillets, herbal granules, and sterile vials containing biologics—within standardized SUS304 trolleys (2 units included). Its chamber geometry and shelf spacing (77 mm) ensure optimal vapor flow path length and uniform heat transfer. The system conforms to ISO 9001:2015 quality management standards and incorporates design elements aligned with FDA 21 CFR Part 11 data integrity expectations—audit trail logging, electronic signature support, and user-access-level permissions. While not certified for pharmaceutical final-fill use out-of-the-box, its mechanical and control architecture supports qualification (IQ/OQ/PQ) under cGMP or WHO-GMP frameworks when commissioned with appropriate validation protocols.
Software & Data Management
The embedded control software provides full lifecycle batch documentation: automatic timestamped recording of all critical process parameters at configurable intervals (1–60 s), exportable in CSV or PDF formats compliant with GLP/GMP record retention policies. Recipes are stored with version control, and modification history—including operator ID, timestamp, and parameter delta—is retained indefinitely. Remote diagnostics and firmware updates are supported over secure TLS-encrypted connections. Optional integration with MES/SCADA systems is available via Modbus TCP or OPC UA interfaces. All data resides locally on the IPC’s encrypted SSD; cloud backup is configurable but disabled by default to preserve data sovereignty.
Applications
- Food processing: Stabilization of anthocyanin-rich hawthorn slices, preservation of delicate basidiomycete morphology in shiitake and oyster mushrooms, production of rehydratable pet treats with retained palatability and digestibility.
- Botanicals & nutraceuticals: Low-temperature dehydration of ginseng, goji berry, and cordyceps extracts without Maillard degradation or oxidation of active polysaccharides and triterpenoids.
- Biotechnology: Primary drying of cell culture supernatants, enzyme preparations, and diagnostic reagent kits requiring residual moisture < 2 % w/w.
- Research & pilot manufacturing: Scalable process development from lab-scale (≤ 0.5 m²) to production batches, supporting DOE-based optimization of shelf temperature ramps, vacuum ramp rates, and primary drying endpoints.
FAQ
Is the TF-FZG-50 suitable for sterile pharmaceutical manufacturing?
It meets mechanical and material prerequisites for aseptic processing environments but requires site-specific qualification (IQ/OQ/PQ), sterilization validation (e.g., SIP cycle), and integration with isolator or RABS infrastructure to comply with Annex 1.
Can shelf temperature be controlled independently per zone?
No—the current configuration features uniform shelf temperature control across all layers; zonal control is available as a factory option with additional thermocouple mapping and PID loop segmentation.
What utilities are required for installation?
Three-phase 380 V ±10 %, 50 Hz power supply; chilled water inlet (≤ 12 °C) for condenser cooling; compressed air (≥ 0.6 MPa) for valve actuation; optional steam supply for in-place defrosting.
Does the system support automated defrost cycles?
Yes—programmable defrost modes include hot gas injection, steam-assisted, or immersion-type cycles, each with configurable duration, temperature ramp, and condensate drainage timing.
What is the typical lead time after order confirmation?
Standard delivery is 5–7 working days for in-stock configurations; custom engineering (e.g., non-standard shelf layout, enhanced corrosion resistance, or explosion-proof certification) extends lead time to 8–12 weeks.
