Tianfeng TF-FZG-20 Industrial-Scale Freeze Dryer
| Brand | Tianfeng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Equipment Type | Standard Shelf-Type Freeze Dryer |
| Application Scope | Production-Scale |
| Freeze-Drying Area | 20 m² |
| Ultimate Vacuum | 2.7 Pa |
| Condensate Capacity (24 h) | 400 kg |
| Cold Trap Temperature | −60 °C |
| Main Unit Dimensions | 7600 × 2100 × 3600 mm |
Overview
The Tianfeng TF-FZG-20 is an industrial-scale, shelf-type freeze dryer engineered for reproducible, high-throughput lyophilization of thermolabile materials—including herbal extracts, botanicals (e.g., matsutake mushrooms), functional food ingredients, biopharmaceutical intermediates, and nutraceutical powders. It operates on the fundamental principle of sublimation: frozen water in the product matrix is removed under controlled low-pressure (< 3 Pa) and low-temperature (cold trap at −60 °C) conditions, bypassing the liquid phase entirely. This preserves structural integrity, bioactivity, volatile compound profiles, and reconstitution kinetics—critical for GMP-compliant production of active pharmaceutical ingredients (APIs), standardized botanical extracts, and clinical-grade diagnostics reagents.
Key Features
- Stainless steel 304 construction throughout the drying chamber and shelves, with mirror-finish electropolished interior surfaces to ensure cleanability, corrosion resistance, and compliance with ISO 14644-1 Class 8 (ISO Class 5 at critical zones with optional laminar flow)
- High-efficiency refrigeration system incorporating imported compressors and optimized cascade cooling architecture, enabling stable cold trap operation at −60 °C continuously for ≥24 h
- Dual-stage vacuum system with pump-trap isolation, gas ballast control, and programmable backfill regulation—ensuring precise pressure ramping from atmospheric to ≤2.7 Pa with minimal oil carryover
- Electrically heated shelves with silicone oil thermal transfer medium; temperature range: −45 °C to +80 °C; uniformity ±1.5 °C across full shelf surface per ASTM F2699
- PLC-based control system with HMI touchscreen interface supporting manual/automatic modes, recipe storage (≥100 programs), real-time trend logging, and remote monitoring via Ethernet or optional 4G module
- Integrated safety protocols including overtemperature cutoff, low-pressure interlock, motor overload protection, and emergency stop circuitry compliant with IEC 61000-6-2/6-4 EMC standards
Sample Compatibility & Compliance
The TF-FZG-20 accommodates batch loads up to 200 kg (wet weight) of pre-frozen material across its 20 m² shelf area. It supports vial, tray, and bulk-container configurations for raw herbs, concentrated extracts, fermented broths, enzyme solutions, probiotic suspensions, and marine collagen hydrolysates. The system meets core requirements for Good Manufacturing Practice (GMP) environments per WHO TRS 986 Annex 6 and EU GMP Annex 15. Data integrity conforms to FDA 21 CFR Part 11 through audit-trail-enabled electronic records, user-level access control, and non-editable event logs. All wetted parts comply with USP and ISO 8536-4 for pharmaceutical container compatibility.
Software & Data Management
The embedded control software provides full-cycle process definition: freezing rate profiling, primary drying hold points, secondary drying ramping, and endpoint detection via pressure rise test (PRT) or product temperature monitoring. Exportable CSV and PDF reports include time-stamped temperature, pressure, condenser load, and shelf power data—formatted for direct import into LIMS or MES platforms. Optional validation packages include IQ/OQ documentation templates aligned with ASTM E2500 and ISO 13485 for medical device manufacturers.
Applications
- Standardized extraction and stabilization of Tricholoma matsutake polysaccharides and aroma volatiles without Maillard degradation
- Lyophilization of aqueous herbal decoctions (e.g., Ganoderma lucidum, Epimedium sagittatum) into dispersible granules meeting Chinese Pharmacopoeia ChP 2020 moisture limits (≤5.0%)
- Production of sterile-grade vaccine adjuvants and monoclonal antibody formulations requiring residual moisture <1.0% w/w
- Bulk drying of pet food functional additives (e.g., prebiotics, omega-3 microcapsules) while retaining oxidative stability (per AOAC 972.16)
- Processing of seafood hydrolysates and collagen peptides for nutraceutical applications where enzymatic activity retention is validated by spectrophotometric assay (A280/A260 ratio)
FAQ
What is the maximum allowable residual moisture for herbal extract batches processed on the TF-FZG-20?
Residual moisture can be consistently reduced to ≤2.0% w/w for most botanical matrices using optimized secondary drying cycles; final specification depends on formulation and target shelf life.
Does the system support steam-in-place (SIP) sterilization?
No—this model is designed for aseptic processing environments; SIP capability requires optional jacketed chamber and integrated CIP/SIP skid (available as TF-FZG-20-SIP variant).
Can the PLC interface integrate with SCADA systems?
Yes—Modbus TCP and OPC UA protocols are supported natively; custom MQTT or REST API integration is available upon request.
What validation documentation is provided with shipment?
Factory acceptance test (FAT) report, material certifications (EN 10204 3.1), electrical safety certificate (IEC 61010-1), and full mechanical drawings are included; site qualification (SAT) support is offered separately.
Is remote diagnostics available?
Yes—via secure TLS-encrypted VNC connection with prior customer authorization; diagnostic logs include compressor discharge temps, vacuum gauge calibration status, and PID loop variance metrics.
