AYAN F100 Short-Path Molecular Distillation System

Overview

The AYAN F100 Short-Path Molecular Distillation System is an engineered vacuum separation platform designed for high-precision purification of thermally labile, high-boiling-point, and oxidation-sensitive compounds. Operating under ultra-high vacuum conditions (≤1 Pa), the system leverages molecular distillation principles—where the mean free path of vapor molecules exceeds the distance between the evaporating surface and the condensing surface—to achieve separation based on differences in molecular volatility rather than boiling point. Unlike conventional fractional or vacuum distillation, this technique eliminates bulk boiling, foaming, and prolonged thermal exposure. The AYAN F100 integrates a vertically oriented, double-jacketed cylindrical evaporator (100 mm internal diameter), a centrally mounted internal condenser (0.25 m² active area), and a precision-engineered rotating wiper assembly that forms a uniform, sub-millimeter-thick turbulent liquid film (<0.5 mm) across the heated surface. This architecture ensures rapid mass transfer, minimal residence time (<60 seconds typical), and exceptional thermal control—critical for preserving molecular integrity in sensitive natural product isolates.

Key Features

• Ultra-high vacuum capability (≤1 Pa) enabled by integrated dual-stage vacuum system with 2 L/s pumping speed, ensuring low partial pressure environments essential for molecular-scale separation
• Heated evaporator cylinder (SS316L) with precise temperature control from ambient to 300 °C, compatible with high-temperature feedstocks including waxes, sterols, and polymer intermediates
• Internally cooled condenser operating at −20 °C (primary) and −5 °C (secondary), optimized for efficient capture of volatile fractions without re-evaporation
• PTFE-coated SS316L wiper blades mounted on a balanced rotor (300 rpm), delivering consistent thin-film formation and eliminating channeling or dry spots
• Dual independent collection flasks (2 × 2 L capacity) with individual outlet valves, enabling parallel fractionation or sequential multi-stage separation
• Modular sealing design using food-grade silicone gaskets; optional perfluoroelastomer (FFKM) or PTFE-faced seals available for aggressive solvents or acidic feeds
• Integrated pre-heating feed tank (optional) with PID-controlled heating up to 300 °C, minimizing thermal shock during introduction to the evaporator zone
• No boiling, no bubbling: operation occurs exclusively via surface evaporation under laminar flow conditions—eliminating decomposition pathways associated with nucleate boiling

Sample Compatibility & Compliance

The AYAN F100 is validated for use with heat-sensitive natural extracts (e.g., rose otto, lavender oil, citrus terpenes), polyunsaturated lipids (fish oil EPA/DHA concentrates), pharmaceutical actives (vitamin A/E esters, amino acid derivatives), and synthetic intermediates (epoxy resins, silicone monomers). Its all-SS316L wetted path and inert PTFE contact surfaces comply with USP material compatibility guidelines for pharmaceutical processing equipment. While not certified to ISO 9001 or FDA 21 CFR Part 11 out-of-the-box, the system supports GLP/GMP-aligned documentation protocols—including manual logbooks, calibration traceability for temperature and vacuum sensors, and audit-ready operational records when integrated with external data acquisition systems. It meets ASTM D2879-19 requirements for molecular distillation apparatus performance verification under reduced pressure.

Software & Data Management

The AYAN F100 operates via analog-digital hybrid control: digital PID controllers manage heater jacket temperature, condenser cooling setpoints, and rotor speed, while vacuum level is monitored via a calibrated Pirani/capacitance manometer with 0.1 Pa resolution. Real-time parameters are displayed on a front-panel LCD interface with password-protected configuration access. Although no embedded software suite is included, analog outputs (4–20 mA) for temperature, pressure, and RPM enable seamless integration with third-party SCADA or LIMS platforms (e.g., LabVIEW, DeltaV, or custom Python-based logging). All critical process variables can be recorded at 1 Hz intervals using external DAQ hardware, supporting full traceability required under ISO/IEC 17025-compliant testing laboratories.

Applications

• Fine chemical purification: isolation of mono-terpenes from crude essential oils, removal of peroxides from unsaturated fatty acids, and deacidification of triglyceride feedstocks
• Pharmaceutical manufacturing: recovery of heat-labile vitamins (A, E, K), purification of chiral intermediates, and solvent removal post-extraction without racemization
• Food & nutraceutical processing: concentration of omega-3 concentrates from fish oil, deodorization of edible oils, and separation of phytosterol esters from tall oil pitch
• Materials science: purification of liquid crystal monomers, monomer recovery from polymerization residues, and isolation of high-purity silicone fluids
• Environmental analysis: cleanup of PAH-contaminated extracts prior to GC-MS quantification, and isolation of bioactive fractions from microalgal lipid extracts

FAQ

What is the maximum allowable feed viscosity for stable thin-film formation?
For optimal wiper performance and uniform film thickness, feed viscosity should not exceed 500 cP at processing temperature. Pre-heating the feed tank mitigates viscosity-related issues for waxy or semi-solid samples.
Can the AYAN F100 be used under inert gas purge?
Yes—the system includes dedicated gas inlet/outlet ports compatible with nitrogen or argon blanketing to further suppress oxidative degradation during distillation.
Is validation support provided for regulatory submissions?
AYAN supplies factory calibration certificates for all primary sensors (temperature, pressure) and mechanical drawings compliant with ASME BPE-2022 dimensional standards. IQ/OQ documentation templates are available upon request for user-executed qualification.
How is residue removal handled after a run?
The evaporator cylinder features a bottom discharge valve with a quick-release sanitary clamp, allowing full drainage of heavy residue into an external receiver without disassembly.
What maintenance intervals are recommended for the vacuum pump and condenser coils?
Vacuum pump oil should be changed every 200 operational hours; condenser coils require descaling with dilute citric acid solution every 50 runs when processing mineral-rich or salt-containing feeds.