AYAN-B150 AnYan Short-Path Molecular Distillation System with Wiped-Film Evaporator

Overview

The AYAN-B150 AnYan Short-Path Molecular Distillation System is a precision-engineered wiped-film evaporator designed for high-efficiency, low-thermal-stress separation of thermolabile, high-viscosity, and oxidation-sensitive compounds under ultra-high vacuum conditions. Unlike conventional distillation or rotary evaporation, this system operates on the principle of short-path molecular distillation—where evaporated molecules travel directly from the heated film surface to the condenser (distance < mean free path), minimizing residence time and thermal degradation. The core component is a vertically oriented, jacketed cylindrical evaporator with an internal diameter of 150 mm and an effective heating surface area of 0.25 m². A motor-driven, adjustable-speed rotor (≤450 rpm) supports a set of radial PTFE-coated stainless steel (SS316L) wiper blades that continuously renew the liquid film on the heated wall at a controlled thickness (<0.5 mm). This ensures uniform heat transfer, high evaporation intensity (~200 kg/m²·hr), and reproducible separation performance across batch and continuous feed modes.

Key Features

• Ultra-high vacuum capability: Integrated vacuum system achieves stable operating pressure < 0.1 Pa—critical for preserving molecular integrity in heat-sensitive actives such as vitamins (A, E), polyunsaturated fatty acids (PUFAs), and labile phytochemicals.
• Wiped-film architecture: SS316L evaporator body with PTFE-blade assembly enables reliable operation with viscous feeds (up to 10⁴ cP), crystallizing solutes, and fouling-prone matrices without clogging or thermal runaway.
• Modular thermal control: Electrically heated jacket (ambient to 200 °C) with PID-regulated temperature stability ±1.0 °C; optional pre-heating feed vessel with independent temperature setpoint.
• Optimized condensation geometry: 0.45 m² concentric internal condenser with dual-stage cooling interface—compatible with external recirculating chillers (−20 °C to −80 °C) for high-efficiency vapor capture.
• Chemically inert fluid path: All wetted surfaces constructed from SS316L and fluoropolymer components; KF/VCR-compatible ports sealed with FKM gaskets (PTFE gasket upgrade available for aggressive solvents).
• Compact footprint & cleanability: Fully accessible rotor assembly, quick-release flanges, and smooth internal surfaces facilitate GMP-aligned cleaning validation and routine maintenance.

Sample Compatibility & Compliance

The AYAN-B150 accommodates diverse feedstocks across pharmaceutical, nutraceutical, fine chemical, and environmental laboratories—including but not limited to fish oil concentrates, lanolin derivatives, polymer intermediates, fragrance oils, pesticide residues in extracts, and solvent-washed botanical fractions. Its design supports GLP-compliant operation when integrated with validated vacuum gauges, temperature loggers, and feed flow controllers. While not pre-certified to ISO 21789 or ASTM D6304, the system’s mechanical construction, material traceability (EN 10204 3.1), and vacuum integrity meet baseline requirements for method development under USP , ICH Q5C, and FDA 21 CFR Part 11–enabled data acquisition systems (when paired with compliant third-party software).

Software & Data Management

The AYAN-B150 operates via a dedicated industrial-grade touchscreen HMI with local data logging (temperature, vacuum, rotation speed, runtime) stored on internal SD card (CSV export). For regulated environments, analog outputs (4–20 mA) and Modbus RTU RS485 enable integration into SCADA or LIMS platforms. Audit trail functionality—including user login timestamps, parameter change logs, and alarm history—is available when connected to AnYan’s optional AnDistilControl Suite v3.x, which supports electronic signatures, 21 CFR Part 11–compliant user role management, and PDF report generation with embedded calibration certificates.

Applications

• Fine chemical purification: Isolation of aroma compounds (e.g., rose oxide, ionones), removal of catalyst residues from polycondensation intermediates, and deacidification of tall oil fatty acids.
• Pharmaceutical processing: Recovery of natural vitamin E acetate from soybean distillates; purification of amino acid derivatives (e.g., N-acetyl-L-cysteine); stabilization of retinoids during API intermediate refinement.
• Food & nutraceutical manufacturing: Concentration of omega-3 EPA/DHA from crude fish oil; decolorization and deodorization of rice bran oil; fractionation of mixed sterols and squalene.
• Environmental analysis: Solvent exchange and concentrate cleanup prior to GC-MS analysis of PAHs or PCBs in soil/sediment extracts.
• Polymer science: Devolatilization of silicone prepolymers; removal of unreacted monomers from acrylic resins; purification of bio-based plasticizers (e.g., acetyl tributyl citrate).

FAQ

What vacuum level is required for optimal molecular distillation performance?
Operation below 0.1 Pa is recommended to ensure mean free path exceeds the evaporator-to-condenser distance—typically 40–60 mm—thereby enabling true molecular regime separation.
Can the AYAN-B150 handle feed materials with solid particulates?
Pre-filtration (≤5 µm) is mandatory; the system is not designed for slurry or suspended solids. Clogging of the wiper gap or feed line may compromise film formation and thermal uniformity.
Is feed pre-heating necessary?
Pre-heating improves initial film formation and reduces thermal shock—especially for high-viscosity feeds (>500 cP at 40 °C). The optional pre-heater vessel supports temperature control from ambient to 120 °C.
How is cleaning validated for GMP applications?
The unit supports swab sampling and rinse recovery studies per USP . SS316L surfaces are electropolished (Ra ≤ 0.4 µm), and all gasketed joints use documented extractables profiles per USP .
Does AnYan provide IQ/OQ documentation templates?
Yes—standard qualification protocols (including sensor calibration records, vacuum leak test procedures, and temperature mapping reports) are supplied with each unit upon request.