Tianfeng TF-FZG-10 Industrial-Scale Freeze Dryer for Herbal & Food Applications

Overview

The Tianfeng TF-FZG-10 is an industrial-scale, in-situ freeze dryer engineered for high-reliability lyophilization of heat-sensitive biological and food materials—including goji berries, ginseng root, royal jelly, herbal extracts, and functional food matrices. Operating on the fundamental principle of sublimation under deep vacuum and cryogenic condensation, this system removes water from frozen samples without passing through the liquid phase—preserving structural integrity, bioactive compounds (e.g., polysaccharides, flavonoids, saponins), enzymatic activity, and volatile aroma profiles. Designed for GMP-aligned production environments, the TF-FZG-10 integrates primary drying (sublimation) and secondary drying (desorption) within a single, sealed chamber, eliminating manual transfer and contamination risk. Its robust stainless-steel construction (AISI 304 contact surfaces), double-walled insulated chamber, and high-efficiency refrigeration circuit support continuous batch processing at scale—making it suitable for pilot-to-production transition in nutraceutical, traditional medicine, and premium food manufacturing.

Key Features

• In-situ freezing and drying: Eliminates sample handling between pre-freezing and lyophilization stages—reducing cross-contamination and process variability.
• Precision shelf temperature control: Circulating thermal fluid system maintains ≤ ±1 °C uniformity across all 8 shelves (7 active + 1 base), enabling reproducible drying kinetics and consistent product morphology.
• PLC-based automation with 10.4″ HMI touchscreen: Supports recipe-driven operation, real-time parameter logging (shelf temp, chamber pressure, condenser temp), alarm management, and event-triggered data capture.
• Remote connectivity & data traceability: Ethernet-enabled interface allows secure remote monitoring, curve export (CSV/Excel), and integration into centralized MES or LIMS platforms; audit trail functionality complies with FDA 21 CFR Part 11 requirements when configured with user authentication and electronic signature modules.
• Modular integrated design: Compact footprint (900 × 1600 mm base), factory-assembled refrigeration loop, and standardized utility interfaces simplify site installation, validation (IQ/OQ), and future scalability.

Sample Compatibility & Compliance

The TF-FZG-10 accommodates diverse sample formats—bulk solutions (up to 100 L per cycle), tray-loaded herbs (e.g., whole goji berries, sliced ginseng), vials (2–50 mL), and irregular botanicals—without requiring formulation additives or structural supports. Its −65 °C condenser and 2.7 Pa ultimate vacuum meet ISO 22052-1:2021 specifications for pharmaceutical-grade lyophilizers and support compliance with USP , EP 2.9.40, and Chinese Pharmacopoeia IV (2020) lyophilization validation guidelines. For food applications, the system conforms to ISO 20483:2013 (determination of moisture content in dried foods) and supports HACCP-based process hazard analysis. All wetted parts comply with FDA 21 CFR 177.2600 (food-contact polymers) and EU Regulation (EC) No. 1935/2004.

Software & Data Management

Tianfeng’s proprietary LyoControl™ software provides full-cycle process supervision—including dynamic vacuum ramping, shelf temperature profiling, pressure rise test (PRT) execution, and endpoint determination via capacitance manometry. Data are timestamped, encrypted, and stored locally on an industrial SSD with ≥10-year retention capacity. Export functions support CSV, PDF report generation, and direct SQL database push. Optional 21 CFR Part 11 compliance package includes role-based access control (RBAC), electronic signatures, and immutable audit logs—validated for GLP/GMP-regulated environments. All firmware updates are delivered via signed OTA packages with SHA-256 verification.

Applications

• Nutraceutical & Traditional Medicine: Stabilization of goji polysaccharides (LBP), ginsenosides (Rb1, Rg1), and Cordyceps sinensis mycelium—retaining >92% antioxidant capacity post-lyophilization (per ABTS/DPPH assays).
• Functional Food Manufacturing: Preservation of anthocyanins in berry powders, vitamin C in citrus concentrates, and probiotic viability in fermented dairy matrices.
• Biopharmaceutical Intermediates: Bulk drying of monoclonal antibody formulations, viral vectors, and cell lysates prior to aseptic filling.
• Research & Repository Use: Long-term stabilization of microbial cultures, plant germplasm, and archival tissue specimens—validated for >5-year room-temperature storage stability under nitrogen-flushed packaging.

FAQ

What is the maximum batch capacity for goji berries in whole-fruit form?
Typical loading density is 8–12 kg/m² on shelves; for 10 m² area, up to 120 kg of fresh goji berries (≈30–35 kg dry weight) can be processed per cycle.
Can the system be validated for GMP production?
Yes—the TF-FZG-10 is supplied with FAT/SAT documentation, IQ/OQ protocol templates, and optional PQ support services aligned with Annex 15 and WHO TRS 986.
Is custom shelf configuration available?
Yes—Tianfeng offers engineering customization including perforated shelves, silicone-coated trays, and integrated load-cell weighing systems upon request.
What cooling infrastructure is required?
A closed-loop cooling tower or chiller delivering 18 m³/h at 25–30 °C inlet temperature is mandatory; glycol-water (30% propylene glycol) is recommended for ambient temperatures below 5 °C.
Does the system support automatic defrost cycles?
Yes—programmable condenser defrost (hot-gas or electric heater assisted) is integrated and configurable per cycle without interrupting shelf temperature stability.