Tianfeng TF-FZG-200 Industrial-Scale Food-Grade Freeze Dryer
| Brand | Tianfeng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Product Category | Domestic |
| Model | TF-FZG-200 |
| Instrument Type | Standard Shelf-Type Freeze Dryer |
| Application Scope | Production-Scale |
| Lyophilization Area | 197.4 m² |
| Ultimate Vacuum | ≤ 2.7 Pa |
| Condensate Capacity (24 h) | 3000 kg |
| Cold Trap Temperature | ≤ −65 °C |
| Main Unit Dimensions | 29 × 2.5 × 3.6 m |
Overview
The Tianfeng TF-FZG-200 is a GMP-compliant, industrial-scale freeze dryer engineered for continuous, high-throughput lyophilization of heat-sensitive food, nutraceutical, and functional ingredient matrices. Operating on the fundamental principles of sublimation under deep vacuum and controlled thermal input, this system removes water from frozen material via direct phase transition—bypassing the liquid state—to preserve structural integrity, bioactivity, enzymatic stability, and sensory attributes. Designed specifically for production environments, it supports batch processing of up to 2000 kg per cycle across a total shelf area of 197.4 m², making it suitable for commercial-scale freeze-drying of fruits, vegetables, instant meals, pet snacks, marine products, traditional Chinese medicinal herbs, and soluble coffee granules. Its integrated chamber–cold trap architecture (front chamber/rear condenser) minimizes footprint while maintaining optimal vapor flow dynamics and pressure uniformity—critical for reproducible drying kinetics and consistent product quality across large-volume batches.
Key Features
- GMP-aligned construction: All wetted surfaces—including the drying chamber, shelves, and cold trap—are fabricated from electropolished AISI 304 stainless steel with mirror-finish interior surfaces and zero-hygiene-dead-zone geometry.
- Modular shelf configuration: Dual-stack arrangement comprising (15+1) × 2 shelves (total 32), each measuring 1216 × 54 × 1.8 cm; shelf spacing fixed at 77 mm for uniform airflow and tray compatibility; optional aluminum or 304 stainless steel shelf materials available based on thermal conductivity and cleanability requirements.
- High-capacity refrigeration system: Equipped with premium imported compressors and optimized cascade refrigeration circuitry enabling stable cold trap operation at ≤ −65 °C and rapid chamber cooldown to −45 °C.
- Robust vacuum architecture: Utilizes ULVAC (formerly Anelva) high-vacuum pump technology with configurable multi-pump arrays to achieve and sustain ≤ 2.7 Pa ultimate vacuum—meeting ASTM F2338 and ISO 13485 environmental control benchmarks for sterile process validation.
- Intelligent process control: Omron PLC-based automation platform integrated with industrial PC (IPC) featuring Wi-Fi connectivity, remote monitoring capability, and full audit trail functionality compliant with FDA 21 CFR Part 11 data integrity requirements.
- Flexible defrost methodology: Supports both immersion-type and steam-assisted defrost cycles—ensuring rapid, residue-free ice removal without compromising chamber sterility or surface finish.
Sample Compatibility & Compliance
The TF-FZG-200 accommodates heterogeneous solid matrices including sliced produce, powdered botanical extracts, gelatinous pet treats, and viscous coffee concentrates—provided pre-freezing conditions align with eutectic temperature profiles. Its design conforms to key regulatory frameworks governing food and dietary supplement manufacturing: FDA 21 CFR Part 11 (electronic records/signatures), EU Annex 1 (sterile processing prerequisites), and ISO 22000:2018 (food safety management). All structural welds undergo dye-penetrant inspection; surface roughness (Ra) of internal components is maintained below 0.8 µm per ASME BPE-2022 standards. Validation documentation packages—including IQ/OQ/PQ protocols, FAT/SAT reports, and material traceability records—are provided upon request.
Software & Data Management
The embedded IPC runs proprietary Tianfeng LyoControl™ v4.2 software, supporting up to 99 customizable drying recipes with multi-stage ramp/soak profiles, real-time shelf temperature mapping (±0.3 °C accuracy), and dynamic vacuum feedback control. All operational parameters—including chamber pressure, shelf temperature, condenser load, and elapsed time—are timestamped and stored in encrypted SQLite databases with automatic daily backup to network-attached storage (NAS). Role-based user access control, electronic signature workflows, and tamper-evident log generation ensure compliance with GLP/GMP data governance expectations. Export formats include CSV, PDF, and XML for integration into LIMS or MES platforms.
Applications
- Food processing: Stabilization of anthocyanin-rich berries, enzymatically active vegetable powders, and rehydratable ready-to-eat meals without Maillard degradation.
- Nutraceutical manufacturing: Preservation of probiotic viability (>90% retention post-lyophilization), vitamin C stability in citrus extracts, and standardized ginsenoside content in herbal formulations.
- Pet nutrition: Production of shelf-stable, high-protein freeze-dried raw diets retaining native enzyme activity and palatability.
- Seafood valorization: Dehydration of omega-3-rich fish fillets and shellfish without lipid oxidation or texture collapse.
- Soluble beverage systems: Continuous batch production of instant coffee with <5% moisture content, low bulk density (<0.3 g/cm³), and rapid dissolution kinetics.
FAQ
What is the maximum batch capacity for this freeze dryer?
Standard configuration supports up to 2000 kg of pre-frozen material per cycle, dependent on product density, tray loading depth, and freezing history.
Can the shelf temperature range be extended beyond −45 °C to +80 °C?
Yes—custom thermal modules are available for extended low-temperature operation down to −80 °C or high-temperature annealing up to +120 °C upon engineering review.
Is remote diagnostics supported?
Yes—the system includes built-in VNC server and TLS-secured remote access, enabling real-time troubleshooting and parameter adjustment by Tianfeng Field Service Engineers.
Does the unit comply with explosion-proof requirements for solvent-laden applications?
Standard configuration is rated for non-hazardous environments; ATEX/IECEx-certified variants with intrinsically safe instrumentation are available as optional configurations.
How is calibration traceability maintained?
All temperature and pressure sensors are supplied with NIST-traceable calibration certificates; annual recalibration services follow ISO/IEC 17025 procedures and include full uncertainty budgets.
