TF-Feng TF-FZG-5 Benchtop Industrial Freeze Dryer – In-Situ Pre-Freezing & Primary Drying System
| Brand | TF-Feng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Region of Origin | Domestic (China) |
| Model | TF-FZG-5 |
| Instrument Type | Standard Shelf-Type Freeze Dryer |
| Application Scope | Pilot-Scale Production & Laboratory R&D |
| Shelf Area | 5.13 m² |
| Ultimate Vacuum | ≤2.7 Pa |
| Condenser Temperature | ≤−65 °C |
| Ice Capacity (24 h) | 100 kg |
| Shelf Dimensions (W × D) | 900 mm × 950 mm |
| Shelf Quantity | 7 (6 working + 1 bottom support) |
| Shelf Spacing | 65 mm |
| Shelf Temperature Range | −45 °C to +70 °C |
| Total Power Consumption | 31.0 kW |
| Cooling Water Requirement | 11 m³/h |
| Unit Weight | 5 T |
Overview
The TF-Feng TF-FZG-5 is a fully integrated, in-situ freeze dryer engineered for pilot-scale production and advanced laboratory research in pharmaceutical, nutraceutical, food science, and traditional Chinese medicine (TCM) applications. It operates on the fundamental principles of lyophilization—sequential freezing under controlled conditions, followed by primary drying via sublimation under high vacuum, and secondary drying to remove unfrozen bound water. This process preserves thermolabile compounds, volatile aromatics, enzymatic activity, and structural integrity far more effectively than conventional thermal drying methods. Designed with a 5.13 m² total shelf area and a condenser capacity of 100 kg ice per 24 hours, the TF-FZG-5 bridges the gap between benchtop feasibility studies and early-stage manufacturing validation—supporting reproducible batch processing of herbal extracts, floral biomass, functional food matrices, and biologically active solutions.
Key Features
- In-situ pre-freezing and drying: Eliminates manual transfer between freezing and drying chambers, minimizing contamination risk and preserving sample morphology.
- Seven stainless-steel shelves with ±0.5 °C uniformity (≤1 °C max deviation across surface), actively controlled via dual-circuit silicone oil circulation for precise ramp-and-hold temperature profiles.
- PLC-based automation with 10.4-inch industrial touchscreen HMI, supporting multi-step programmable cycles, real-time parameter logging, and alarm-triggered safety interlocks.
- Integrated vacuum system achieving ≤2.7 Pa ultimate pressure, compliant with ISO 20514:2020 standards for vacuum performance verification in lyophilization equipment.
- Modular design with standardized flange interfaces enables seamless integration of optional CIP (Clean-in-Place) and SIP (Sterilize-in-Place) subsystems, meeting core requirements for GLP-compliant and GMP-aligned workflows.
- Hydraulic stoppering interface compatible with standard 28 mm or 32 mm rubber stoppers, supporting aseptic vial loading and partial stopper seating prior to drying.
Sample Compatibility & Compliance
The TF-FZG-5 accommodates diverse sample formats—including bulk solutions (up to 50 L per cycle), trays of cut flowers or sliced botanicals, TCM decoction concentrates, and pre-filled glass vials—without requiring formulation reformulation. Its −65 °C condenser ensures efficient capture of water vapor from low-eutectic-point matrices such as honey-based extracts or polysaccharide-rich herbal infusions. The system meets mechanical and electrical safety requirements per IEC 61010-1 and supports audit-ready documentation for FDA 21 CFR Part 11 compliance when paired with validated data acquisition software. All wetted surfaces are electropolished 316L stainless steel, certified per ASTM A967 for passivation and corrosion resistance.
Software & Data Management
Data acquisition is performed via embedded Ethernet-enabled PLC with OPC UA server capability, enabling secure bidirectional communication with third-party SCADA or MES platforms. Freeze-drying curves—including shelf temperature, chamber pressure, condenser temperature, and product thermocouple readings—are timestamped and stored locally with SHA-256 hash integrity verification. Export formats include CSV and PDF reports compliant with ALCOA+ principles (Attributable, Legible, Contemporaneous, Original, Accurate, Complete, Consistent, Enduring, Available). Remote monitoring and cycle initiation are supported through TLS-encrypted web interface access, configurable within corporate firewall policies.
Applications
- Stabilization of heat-sensitive TCM extracts (e.g., glycosides from Ginseng radix, polysaccharides from Lentinus edodes) without degradation or Maillard browning.
- Rapid dehydration of delicate floral tissues (roses, lavender, chrysanthemum) while retaining volatile oils, anthocyanin pigments, and cellular architecture for cosmetic and aromatic applications.
- Production of stable intermediate powders from fermented broths, enzyme preparations, and probiotic suspensions for capsule formulation.
- Development of reconstitution-optimized food powders—such as instant soup bases, fruit leathers, and protein-fortified snacks—with >95% rehydration efficiency within 60 seconds.
- Process characterization studies aligned with ICH Q5C and USP <1208> guidance for lyophilized product development.
FAQ
What is the maximum allowable load volume per batch?
The system supports up to 50 L of aqueous solution distributed across 7 shelves, assuming average solids content ≤15% w/v and eutectic temperature ≥−25 °C.
Does the TF-FZG-5 comply with GMP requirements for pharmaceutical use?
Yes—when equipped with IQ/OQ validation protocols, audit-trail-enabled software, and optional SIP/CIP modules, it satisfies Annex 1 and EU GMP Chapter 3 prerequisites for sterile processing equipment.
Can shelf temperature be independently controlled during primary drying?
No—shelves operate in synchronized mode to maintain thermal homogeneity; however, individual shelf sensors enable closed-loop feedback control with ±0.3 °C setpoint accuracy.
Is remote data export possible without physical USB access?
Yes—via secure FTPS or SFTP over configured network infrastructure, with user-role-based permission controls and encrypted archive packaging.
What maintenance intervals are recommended for the vacuum pump and refrigeration system?
Oil-lubricated vacuum pumps require oil change every 500 operational hours; refrigerant charge and compressor oil analysis are advised annually or after 2,000 hours of cumulative runtime.
