Tianfeng TF-FZG-150 Industrial Freeze Dryer

Overview

The Tianfeng TF-FZG-150 Industrial Freeze Dryer is a GMP-compliant, large-scale lyophilization system engineered for continuous batch processing of heat-sensitive food products—including pet snacks, functional foods, dried fruits, ready-to-eat meals, and nutraceuticals. Based on the fundamental principles of sublimation under deep vacuum and controlled thermal input, this unit operates by freezing product loads to −45 °C, then applying a vacuum environment (≤2.7 Pa) to enable direct phase transition from ice to vapor—bypassing the liquid state entirely. With an effective shelf area of 148 m² and a maximum loading capacity of 1.5 metric tons per cycle, the TF-FZG-150 supports high-throughput manufacturing while preserving volatile compounds, enzymatic activity, structural integrity, and nutritional profile. Its integrated front-chamber/rear-condenser architecture minimizes footprint without compromising thermal efficiency or vacuum stability.

Key Features

• GMP-compliant construction: All wetted surfaces—including chamber cylinder, shelves, and condenser coils—fabricated from electropolished AISI 304 stainless steel with mirror-finish interior (Ra ≤ 0.4 µm), conforming to FDA 21 CFR Part 11 and EU Annex 1 hygienic design standards.
• Modular shelf configuration: Dual-stack arrangement with (15 + 1) × 2 shelves (total 32 plates), each measuring 912 × 54 × 1.8 cm; inter-shelf spacing fixed at 77 mm for optimal airflow and uniform heat transfer.
• High-capacity refrigeration system: Dual-stage cascade refrigeration using premium imported compressors; achieves cold trap temperature ≤ −65 °C within ≤120 minutes from ambient start-up; condensate capacity rated at 2000 kg/24 h under ISO 20417-defined test conditions.
• Robust vacuum architecture: Equipped with ULVAC (formerly Ebara) high-efficiency oil-sealed rotary vane pumps and optional diffusion booster stages; vacuum integrity verified per ASTM F2622–18 for pharmaceutical freeze dryers.
• Intelligent control platform: Omron CJ2M PLC paired with industrial PC (IPC) featuring embedded Wi-Fi, remote diagnostics, audit trail logging, and password-protected user roles—fully compliant with 21 CFR Part 11 electronic record requirements.
• Flexible shelf material options: Standard aluminum alloy shelves (extruded, brushed finish) for enhanced thermal conductivity; optional AISI 304 stainless steel shelves for enhanced cleanability and chemical resistance in aggressive cleaning regimes.

Sample Compatibility & Compliance

The TF-FZG-150 accommodates diverse product formats including bulk trays (SUS304 trolleys, 6 units included), stacked pans, and custom molds—suitable for granular pet treats, sliced vegetables, powdered supplements, and pre-formed meal components. Chamber geometry and shelf layout support uniform mass transfer across all load zones, validated via thermocouple mapping per ISO 13485:2016 Annex D. All materials contacting process air or product meet USP Class VI biocompatibility criteria. The system satisfies CE Machinery Directive 2006/42/EC, RoHS 2011/65/EU, and carries ISO 9001:2015 certification for design, production, and service processes.

Software & Data Management

The integrated HMI software enables creation, storage, and execution of up to 256 independent drying protocols, each supporting multi-step ramp/soak profiles for shelf temperature (−45 °C to +80 °C), chamber pressure (0.1–100 Pa), and condenser duty cycles. Real-time data logging records ≥16 channels (shelf temp, chamber pressure, condenser temp, vacuum pump current, etc.) at configurable intervals (1–60 s). Export formats include CSV, PDF, and encrypted binary logs compatible with LIMS integration. Audit trails retain operator ID, timestamp, parameter changes, and recipe modifications—retained for ≥36 months per GLP/GMP retention policies.

Applications

• Commercial-scale production of freeze-dried pet nutrition products meeting AAFCO and FEDIAF compositional guidelines.
• Stabilization of probiotic cultures, botanical extracts, and enzyme formulations requiring residual moisture <2% w/w.
• Processing of delicate fruit pulps, seafood proteins, and dairy-based snacks where color, rehydration ratio, and texture retention are critical quality attributes.
• Contract manufacturing support for FDA-regulated dietary supplement facilities requiring full traceability and validation-ready documentation packages.
• Pre-commercial pilot runs for new product development in food R&D centers operating under ISO/IEC 17025-accredited testing frameworks.

FAQ

Is the TF-FZG-150 suitable for FDA-registered food manufacturing facilities?
Yes—the equipment meets prerequisite design elements outlined in FDA Guidance for Industry: Food Facility Registration and Current Good Manufacturing Practice (CGMP) for Foods, including material traceability, clean-in-place (CIP)-compatible geometry, and electronic record controls aligned with 21 CFR Part 11.
Can shelf temperature be independently controlled per zone?
No—shelves operate in unified thermal zones; however, dual-zone heating/cooling circuits allow simultaneous control of front and rear shelf stacks with ±0.5 °C uniformity across full load.
What validation documentation is supplied with the system?
Factory acceptance test (FAT) report, IQ/OQ protocol templates, calibration certificates for all transmitters (pressure, temperature, vacuum), and material compliance dossiers (EN 10204 3.1) are provided standard.
Does the system support steam sterilization (SIP)?
No—this model is designed for aseptic processing environments using VHP (vaporized hydrogen peroxide) or dry heat decontamination; SIP capability requires optional jacketed chamber configuration.
What is the expected mean time between failures (MTBF) for the refrigeration subsystem?
Based on field data from >120 installed units, MTBF exceeds 18,000 operational hours under continuous 2-shift operation with scheduled preventive maintenance every 2000 hours.