Tianfeng TF-FZG-150 Industrial-Scale Freeze Dryer for Food Processing
| Brand | Tianfeng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Equipment Type | Standard Shelf-Type Freeze Dryer |
| Application Scope | Production-Scale |
| Freeze-Drying Area | 148 m² |
| Ultimate Vacuum | ≤ 2.7 Pa |
| Condensate Capacity (24 h) | 2000 kg |
| Cold Trap Temperature | ≤ −65 °C |
| Main Unit Dimensions (L×W×H) | 25 × 2.5 × 3.6 m |
| Shelf Temperature Range | −45 °C to +80 °C |
| Heating Power (Optional Electric) | 48 kW × 3 |
| Total Installed Power | 380 kW |
| Control System | Omron PLC + Industrial PC with Wi-Fi & Remote Access Capability |
| Weight | 30 t |
Overview
The Tianfeng TF-FZG-150 is an industrial-scale freeze dryer engineered for continuous, high-throughput lyophilization of food-grade materials including fruits, vegetables, ready-to-eat meals, pet nutrition products, and dietary supplements. Designed around the fundamental principles of sublimation-based dehydration under controlled low-pressure and cryogenic conditions, this system operates by freezing product on temperature-regulated shelves, then reducing ambient pressure below the triple point of water while applying precise shelf heating to drive ice sublimation directly into vapor—captured by a deep-cold condenser. Its integrated chamber-and-trap architecture enables efficient mass transfer and thermal uniformity across large batches, supporting up to 1.5 metric tons per cycle. The unit meets structural and material requirements aligned with current Good Manufacturing Practice (cGMP) guidelines for food processing environments, emphasizing cleanability, corrosion resistance, and process repeatability.
Key Features
- Integrated chamber–cold trap design with front-loading chamber and rear-mounted condenser, minimizing footprint while maximizing accessibility and operational efficiency.
- GMP-compliant construction: cylindrical chamber fabricated from mirror-finished AISI 304 stainless steel; internal surfaces electropolished to Ra ≤ 0.4 µm for microbial control and ease of cleaning.
- Customizable shelf configuration: dual-stack arrangement comprising (15+1) × 2 shelves (total 32), with optional aluminum extrusion or 304 stainless steel shelf plates—both engineered for optimal heat transfer and hygienic integrity.
- High-capacity refrigeration system using premium imported compressors and refrigerants, achieving cold trap temperatures ≤ −65 °C within ≤ 90 minutes from ambient start-up.
- Dual-mode defrost system: configurable for either steam-assisted or immersion-type defrosting, ensuring rapid, residue-free regeneration of condenser performance between cycles.
- Modular vacuum train compatible with ULVAC (formerly Anelva) high-vacuum pump technology, delivering stable ultimate vacuum ≤ 2.7 Pa with minimal oil carryover and long-term reliability.
Sample Compatibility & Compliance
The TF-FZG-150 accommodates bulk-loaded trays, stainless steel trolleys (6 units included, SUS304), and standardized food-grade containers. It supports freeze-drying of heat-sensitive biological matrices without thermal degradation, preserving volatile compounds, enzymatic activity, and structural integrity in final products. All wetted components comply with FDA 21 CFR Part 110 (Current Good Manufacturing Practice in Manufacturing, Packing, or Holding Human Food) and ISO 22000:2018 food safety management standards. Surface finish, weld quality, and drainage geometry are validated per ASME BPE-2022 specifications for bioprocessing equipment. Documentation packages include FAT/SAT protocols, material traceability records, and 3.1 mill certificates for all critical pressure parts.
Software & Data Management
Control is executed via an Omron NX-series PLC interfaced with a Windows-based industrial PC running proprietary HMI software. The system supports full recipe management—including multi-step drying profiles with adjustable ramp/soak parameters—and allows real-time modification during operation, including step skipping and dynamic parameter override. Audit trails record all user actions, setpoint changes, alarm events, and data exports with timestamped digital signatures. Data logging complies with FDA 21 CFR Part 11 requirements for electronic records and signatures, including role-based access control, password complexity enforcement, and immutable archive export (CSV/Excel). Optional cloud connectivity enables remote monitoring, predictive maintenance alerts, and integration with MES/SCADA platforms via OPC UA.
Applications
This freeze dryer serves commercial food manufacturing facilities requiring consistent, scalable lyophilization capacity. Typical applications include production of crispy fruit/vegetable snacks, instant soup bases, functional ingredient powders (e.g., green tea polyphenol extracts), freeze-dried pet treats, and nutraceutical tablets. Its wide shelf temperature range (−45 °C to +80 °C) permits primary drying optimization for diverse moisture contents and eutectic behaviors, while the 2000 kg/24 h condensate capacity ensures uninterrupted operation during extended batch runs. The system is routinely deployed in facilities certified to ISO 9001:2015 and HACCP-based food safety plans.
FAQ
Is the TF-FZG-150 suitable for pharmaceutical-grade lyophilization?
No—this model is specifically designed and validated for food-grade applications. Pharmaceutical use would require additional qualification (IQ/OQ/PQ), enhanced containment, and compliance with EU Annex 1 and USP , which are not part of its base configuration.
Can shelf temperature be independently controlled per layer?
No—the system employs zone-based heating; shelves are grouped into two thermally coupled zones (front and rear stacks), each with independent PID control.
What validation documentation is provided upon delivery?
Standard delivery includes Factory Acceptance Test (FAT) report, material certification (EN 10204 3.1), electrical safety certificate (IEC 61000-6-4), and GMP-construction compliance statement. Custom validation support is available under separate service agreement.
Does the system support automated CIP/SIP cycles?
Not natively—clean-in-place (CIP) is supported via external manifold connection; sterilize-in-place (SIP) requires retrofitting with steam jacketing and validated temperature mapping, which is offered as an optional upgrade.
What is the expected mean time between failures (MTBF) for the refrigeration system?
Based on field data from installed units operating under standard food processing duty cycles, MTBF exceeds 12,000 hours for the compressor train when maintained per OEM schedule and ambient conditions remain within specified limits (≤ 35 °C ambient, ≤ 60% RH).
