Tianfeng TF-FZG-15 Industrial-Scale Freeze Dryer

Overview

The Tianfeng TF-FZG-15 is an industrial-scale, shelf-type freeze dryer engineered for high-reliability lyophilization of heat-sensitive food matrices—including fruits, vegetables, edible fungi (e.g., Cordyceps sinensis), enzymatic powders, marine products, pet foods, soup concentrates, functional health supplements, and traditional Chinese medicinal herbs. It operates on the fundamental principles of sublimation-based dehydration: frozen product is subjected to deep vacuum (≤10 Pa) while controlled shelf heating enables ice phase transition directly from solid to vapor—preserving structural integrity, bioactivity, volatile compounds, and nutritional profile without thermal degradation. Designed for continuous batch processing in GMP-aligned production environments, the system integrates a monolithic chamber–condenser architecture with front-chamber/rear-trap configuration, minimizing footprint while maximizing thermal and vacuum efficiency.

Key Features

• GMP-compliant construction: Chamber and shelves fabricated from electropolished 304 stainless steel with mirror-finish interior surfaces, meeting hygienic design standards for food and pharmaceutical applications.
• Integrated condenser system: High-efficiency coil-type condenser built from clean-grade stainless steel; available in monolithic or modular configurations per user requirements.
• Precision temperature control: Shelf temperature range −30 °C to +80 °C with uniformity ±1 °C across all layers; condenser operating temperature ≤−65 °C ensures robust water vapor capture during extended cycles.
• Robust refrigeration architecture: High-performance imported compressors and components deliver rapid cooling ramp rates and stable low-temperature operation under full-load conditions.
• Flexible vacuum generation: Configurable vacuum pump train based on application demand; standard configuration includes ULVAC (formerly Ebara) high-vacuum pumps for reliable long-term operation.
• Intelligent process control: Omron PLC-based system supporting both automatic and manual operation modes; multi-step recipe storage, real-time parameter adjustment during drying, and step-skip functionality for process optimization.
• Ergonomic accessibility: Front-mounted observation window with integrated LED lighting; fully drainable, CIP-compatible structure with zero sanitary dead zones.

Sample Compatibility & Compliance

The TF-FZG-15 accommodates diverse sample formats including bulk trays (up to 15 m² active area), stacked containers, and custom-configured aluminum or 304 stainless steel shelves. Its design conforms to core hygienic engineering principles outlined in ISO 22000, FDA 21 CFR Part 11 (when paired with validated software modules), and EU GMP Annex 15 guidelines for lyophilization process validation. All wetted surfaces comply with FDA 21 CFR 178.3570 (indirect food additives) and ASME BPE-2022 surface finish specifications (Ra ≤ 0.8 µm). The unit supports IQ/OQ/PQ documentation packages upon request and is compatible with GLP/GMP audit trails when operated with time-stamped log export and user-access controls.

Software & Data Management

The embedded Omron NX-series PLC provides deterministic real-time control with non-volatile memory for ≥100 process recipes. System logs record shelf temperature, chamber pressure, condenser temperature, vacuum level, and elapsed time at configurable intervals (1–60 sec). Data export is supported via USB 2.0 and Ethernet (Modbus TCP/IP), enabling integration with LIMS or MES platforms. Optional validation-ready firmware adds electronic signature capability, audit trail logging (per 21 CFR Part 11), and password-protected user roles (Operator, Technician, Administrator). Raw data files are stored in CSV format for traceability and third-party analysis.

Applications

This freeze dryer serves as a primary processing tool in pilot-to-production scale operations requiring preservation of thermolabile biomolecules and sensory attributes. Typical use cases include: stabilization of fruit/vegetable purees into rehydratable powders; low-temperature drying of Cordyceps extracts to retain cordycepin and adenosine content; production of probiotic- and enzyme-rich fermented vegetable powders; dehydration of seafood hydrolysates for flavor enhancer manufacturing; and preparation of herbal decoction concentrates compliant with Chinese Pharmacopoeia standards. Its 200 kg/24h condensation capacity supports batch sizes up to 800–1,200 kg (depending on initial moisture content), making it suitable for contract manufacturing organizations (CMOs) and branded supplement producers.

FAQ

Is the TF-FZG-15 suitable for pharmaceutical-grade lyophilization?
Yes—when equipped with optional validation support packages, IQ/OQ documentation, and configured with appropriate alarms, interlocks, and data integrity features, it meets baseline requirements for Phase I–II clinical trial material production.
Can shelf material be customized beyond aluminum or 304 stainless steel?
Yes—custom coatings (e.g., PTFE-lined shelves) or alternative alloys (e.g., 316L) are available upon engineering review and qualification.
What cooling utility requirements apply?
The system requires chilled water supply ≤25 °C at 10 m³/h; closed-loop chiller integration is recommended for ambient temperatures exceeding 30 °C.
Does Tianfeng provide installation and commissioning support?
Yes—on-site mechanical/electrical commissioning, operational qualification, and operator training are included in turnkey delivery contracts.
How is defrosting performed, and what is cycle time?
Defrosting uses either hot-gas injection or controlled water immersion; typical defrost duration is 45–75 minutes depending on ice load and ambient conditions.