AYAN-B80S Stainless Steel Thin-Film Evaporator

Overview

The AYAN-B80S Stainless Steel Thin-Film Evaporator is a precision short-path molecular distillation system engineered for high-efficiency thermal separation of heat-sensitive, high-viscosity, or thermally labile compounds under high vacuum conditions. It operates on the principle of thin-film evaporation: feed liquid is introduced tangentially into the heated cylindrical evaporator body, where a rotating wiper blade (scraped-surface design) distributes the material into a uniform, turbulent film along the inner wall. Under vacuum (<10 Pa), volatile components rapidly vaporize due to their lower boiling points; vapors travel a short distance—typically <100 mm—to an internal condenser surface, minimizing thermal degradation and residence time (typically 5–15 seconds). Non-volatile residues (heavy fractions) flow downward by gravity and are collected separately. This architecture enables precise fractionation without decomposition—critical for pharmaceutical actives, natural extracts, vitamins, essential oils, and polymer additives.

Key Features

• Robust dual-grade stainless-steel construction: evaporator body, wiper assembly, and condenser fabricated from ASTM-certified 316 and 304 SS for corrosion resistance, ultra-high vacuum integrity, and long-term dimensional stability.
• Scraped-film geometry with adjustable-speed motor (0–450 rpm): ensures consistent film thickness and heat transfer across variable feed viscosities—from 100 cP to >50,000 cP—without channeling or dry-spot formation.
• Integrated high-vacuum compatibility: designed for use with primary vacuum pumps (e.g., two-stage rotary vane or dry scroll) and optional cold traps; achieves and maintains <10 Pa base pressure per ISO 21360-1 verification protocols.
• Modular dual-collection configuration: accommodates two independently removable, calibrated borosilicate glass flasks (standard 1 L capacity each) for simultaneous light- and heavy-fraction recovery under inert atmosphere (N₂ or Ar purge ports available).
• Thermally optimized heating jacket: electrically heated, PID-controlled, with ±1.5 °C uniformity across the 0.1 m² active evaporation surface (max 200 °C); temperature logging supports GLP-compliant process documentation.
• Plug-and-play operation: pre-wired control panel with digital display for rotation speed, jacket temperature, and vacuum status; no external software or calibration tools required for basic operation.

Sample Compatibility & Compliance

The AYAN-B80S is validated for processing thermolabile and viscous feedstocks including but not limited to: botanical extracts (e.g., CBD distillate, tocopherol concentrates), pharmaceutical intermediates (e.g., prostaglandins, peptide derivatives), silicone oils, fatty acid methyl esters (FAME), and polymer oligomers. Its all-metal wetted path complies with USP extractables profiling guidelines when operated within specified temperature and vacuum limits. The system meets mechanical safety requirements per EN 61000-6-2 (EMC immunity) and EN 61000-6-3 (EMC emissions). While not certified to ASME BPVC Section VIII, its pressure boundary design adheres to recognized good engineering practice (GEP) for laboratory-scale vacuum vessels operating below 0.1 MPa differential pressure.

Software & Data Management

The base AYAN-B80S operates via embedded microcontroller logic without proprietary software dependency. Optional RS-485 Modbus RTU interface enables integration with third-party SCADA or LIMS platforms for automated data logging of rotational speed, jacket temperature, and vacuum transducer output (0–10 V analog signal compatible). All operational parameters are timestamped and stored locally in non-volatile memory for up to 72 hours—sufficient for audit trail generation in GLP environments. For FDA 21 CFR Part 11 compliance, users may pair the unit with validated electronic lab notebook (ELN) systems that enforce user authentication, electronic signatures, and audit-log retention.

Applications

• Purification of omega-3 fatty acids (EPA/DHA) from fish oil hydrolysates while preserving cis-configuration integrity.
• Deodorization and decolorization of vegetable oil distillates without stripping natural antioxidants (e.g., γ-oryzanol).
• Isolation of monoacylglycerides from glycerolysis reaction mixtures in emulsifier synthesis.
• Recovery of fragrance volatiles (e.g., linalool, citral) from hydrosols at sub-ambient condenser temperatures (−20 °C optional).
• Preparative-scale removal of residual solvents (e.g., dichloromethane, ethyl acetate) from API solutions prior to lyophilization.
• Stabilization of polyphenol-rich extracts against oxidative polymerization during concentration.

FAQ

What vacuum level is required for optimal performance?
The AYAN-B80S achieves maximum separation efficiency at ≤10 Pa absolute pressure. A two-stage rotary vane pump with gas ballast and inline cold trap is recommended for stable operation.
Can the system handle suspended solids or crystallizing feeds?
Yes—the scraped-film mechanism continuously renews the evaporating surface, preventing fouling and enabling continuous processing of slurries up to 15 wt% solids, provided particle size remains <100 µm.
Is validation documentation available?
Factory-installed calibration certificates for temperature sensor (PT100, traceable to NIST) and vacuum gauge (capacitance manometer) are provided. IQ/OQ protocol templates can be supplied upon request.
What maintenance intervals are recommended?
Wiper blade inspection every 200 operational hours; vacuum seal grease replacement every 6 months; annual verification of heater element resistance and ground continuity.
Does the unit support inert gas sparging?
Yes—dual 1/4″ Swagelok® VCR ports are standard on the feed inlet and top head for nitrogen or argon purging to suppress oxidation during distillation of unsaturated compounds.