Anyan AYAN-F60S Custom-Built Short-Path Molecular Distillation System

Overview

The Anyan AYAN-F60S is a precision-engineered short-path molecular distillation system designed for high-efficiency, low-thermal-stress separation of thermally labile, high-boiling-point, and low-volatility compounds. Unlike conventional vacuum or fractional distillation—processes governed by bulk-phase vapor–liquid equilibrium—the AYAN-F60S operates on the principle of free molecular flow: under ultra-high vacuum (<10 Pa), mean free path exceeds the distance between evaporator and condenser surfaces, enabling direct, non-equilibrium molecular transport from heated film to cold surface. This eliminates boiling, foaming, and thermal degradation risks. The system features a vertically oriented rotating wiper-film evaporator with integrated internal condenser, ensuring sub-second residence time (typically ≤3–5 s), precise temperature control (up to 200 °C), and reproducible thin-film formation across the 60 mm-diameter 316L stainless steel evaporator cylinder. Its compact footprint and modular architecture make it suitable for laboratory-scale process development, pilot validation, and small-batch GMP-compliant purification.

Key Features

• Rotating wiper-film evaporator constructed entirely from electropolished 316L and 304 stainless steel—resistant to corrosion, compliant with USP Class VI and ASTM A276 standards for pharmaceutical and fine chemical processing.
• Short-path geometry with 0.06 m² effective evaporation area and 0.1 m² internal condensing surface—optimized for minimal pressure drop and maximum molecular capture efficiency.
• High-torque, brushless DC motor (120 W, 450 rpm) driving a balanced wiper assembly to generate uniform, controllable liquid films—even for viscous or shear-thinning feedstocks.
• Integrated dual-collection system: two independently cooled, detachable borosilicate glass flasks (1 L each) for simultaneous light-fraction and heavy-fraction recovery under inert atmosphere (N₂ purge port optional).
• Real-time vacuum monitoring via digital Pirani + cold cathode gauge combination; vacuum line includes KF-25 quick-connect fittings and integrated cold trap (−20 °C glycol chiller standard).
• Modular heating mantle with PID-controlled silicon carbide heating elements and multi-zone thermal shielding—ensuring axial temperature uniformity ±2 °C across the evaporation zone.
• Plug-and-play operation with pre-calibrated thermal and rotational interlocks; no manual alignment or vacuum baking required prior to first use.

Sample Compatibility & Compliance

The AYAN-F60S accommodates feed materials ranging from low-viscosity essential oils (e.g., lavender, rose) to highly viscous natural extracts (e.g., tocopherol concentrates, fish oil distillates), polymer additives, and heat-sensitive pharmaceutical intermediates (e.g., cannabinoids, sterols, prostaglandins). It supports batch feeds up to 1 L and continuous throughput of 0.1–0.2 L/h—ideal for method scouting and impurity profiling per ICH Q5, Q7, and USP <721>. All wetted parts meet FDA 21 CFR Part 11 requirements for material traceability and surface finish (Ra ≤ 0.4 µm). The system complies with ISO 9001:2015 manufacturing protocols and is documented for GLP audit readiness—including full calibration certificates for temperature sensors (PT100 Class A), vacuum gauges, and rotational encoder.

Software & Data Management

While the base AYAN-F60S operates via front-panel digital interface (LCD with tactile keypad), optional Anyan DistillSoft™ v3.2 enables PC-based control, real-time data logging (temperature, vacuum, rotation, time), and automated sequence programming (ramp-hold-cool cycles). All operational parameters are timestamped and stored in encrypted CSV/CSVX format with SHA-256 hash integrity verification. Audit trail functionality meets ALCOA+ principles: attributable, legible, contemporaneous, original, accurate, complete, consistent, enduring, and available. Exported datasets are compatible with JMP, MATLAB, and LIMS integration via OPC UA protocol (add-on module).

Applications

• Purification of omega-3 fatty acids (EPA/DHA) from crude fish oil—removing PCBs, dioxins, and monoacylglycerides while preserving cis-configuration integrity.
• Deacidification and deodorization of vegetable oil distillates (e.g., rice bran, sunflower) without trans-fat formation.
• Isolation of natural antioxidants (tocopherols, polyphenols) from botanical extracts under oxygen-free, low-oxygen-transfer conditions.
• Recovery and concentration of fragrance molecules (linalool, citral, ionones) from hydrosols and steam distillates—preserving olfactory fidelity.
• Removal of residual solvents (e.g., hexane, dichloromethane) and catalyst residues from API synthesis intermediates per ICH Q3C guidelines.
• Preparative-scale separation of silicone oligomers, monomer purification for PDMS synthesis, and removal of cyclics from linear polysiloxanes.

FAQ

What vacuum level is required to achieve true molecular distillation conditions?
True molecular distillation requires operating pressure below the mean free path threshold—typically <10 Pa (7.5 × 10⁻² torr) for most organic compounds at 100–200 °C. The AYAN-F60S achieves and sustains this via dual-stage vacuum pump (rotary vane + diffusion or turbomolecular option) and leak-tight KF-25 manifold design.
Can the system handle feedstocks with suspended solids or high viscosity?
Yes—within limits. With optional high-shear wiper blade configuration and pre-heating jacket, the AYAN-F60S processes feeds up to 5,000 cP. Particulates >50 µm must be removed upstream via filtration; inline strainers (100 µm) are recommended for continuous operation.
Is the condenser temperature actively controlled?
The standard configuration uses a recirculating chiller (−20 °C min) connected to the internal condenser jacket. For cryogenic applications (e.g., volatile terpenes), optional LN₂-compatible condenser sleeves are available.
How is cleaning and maintenance performed between runs?
All glass components are removable and autoclavable. Stainless steel surfaces are cleaned in situ using solvent flush (ethanol, acetone) followed by nitrogen purge. Wiper blades are user-replaceable; full maintenance schedule (every 500 h) includes bearing inspection, vacuum seal replacement, and thermal sensor recalibration.
Does the system support regulatory submission documentation?
Yes—Anyan provides IQ/OQ documentation packages (per ASTM E2500), 3Q validation templates, and raw material certifications (EN 10204 3.1) for all critical components. DQ support is available upon request for GMP facility integration.