Tianfeng TF-FZG-20 Industrial-Scale Benchtop Freeze Dryer

Overview

The Tianfeng TF-FZG-20 is an industrial-scale, in-situ shelf-type freeze dryer engineered for high-throughput lyophilization of heat-sensitive biologicals, pharmaceutical intermediates, and food-grade powders—including tea extracts (e.g., black tea), citrus derivatives (e.g., lemon), fruits, and functional food matrices. It operates on the fundamental principle of sublimation: samples are first uniformly frozen on temperature-controlled shelves, then subjected to deep vacuum (≤2.7 Pa) while controlled thermal energy is supplied to facilitate direct phase transition of ice to vapor—bypassing the liquid state. This preserves structural integrity, enzymatic activity, volatile aroma compounds, and nutritional profiles far more effectively than conventional air-drying or spray-drying methods. Designed for GMP-aligned production environments, the system integrates a silicone oil-heated/cooled shelf manifold with ±0.5 °C thermal uniformity across all 9 shelves (8 working + 1 auxiliary), enabling reproducible batch-to-batch performance under validated process parameters.

Key Features

• In-situ pre-freezing and primary/secondary drying within a single chamber—eliminates manual transfer, reduces contamination risk, and ensures process continuity.
• Silicone oil circulation system for precise, stable shelf temperature control (−45 °C to +70 °C); inter-shelf temperature deviation ≤1.0 °C at steady state.
• High-capacity condenser (≤−65 °C) with 400 kg/24 h ice-trapping capacity, optimized for large-volume aqueous solutions (up to 200 L per batch).
• PLC-based control architecture with 10.4-inch industrial touchscreen HMI; real-time monitoring of shelf temperature, condenser temperature, chamber pressure, and time-programmed ramps.
• Full data logging capability compliant with FDA 21 CFR Part 11 requirements: audit trail, user access levels, electronic signatures, and encrypted CSV export of complete lyophilization curves.
• Modular integration-ready design supporting optional CIP (Clean-in-Place) and SIP (Steam-in-Place) subsystems, as well as hydraulic stoppering for vial-based pharmaceutical applications.

Sample Compatibility & Compliance

The TF-FZG-20 accommodates diverse sample formats: bulk trays (standard stainless steel), open pans, and custom-fit containers suitable for fruit purees, herbal infusions, dairy concentrates, probiotic suspensions, and protein-based nutraceuticals. Its 20.24 m² total shelf area supports scalable development from pilot batches to commercial manufacturing. The system meets ISO 9001:2015 quality management standards and conforms to core hygienic design principles outlined in ASME BPE-2022 for equipment used in food and pharmaceutical processing. All wetted surfaces are electropolished 316L stainless steel; vacuum chamber integrity is verified per ASTM E493 helium leak testing protocols. Documentation packages support IQ/OQ/PQ validation activities aligned with ICH Q5C, USP , and EU Annex 1 requirements.

Software & Data Management

The embedded control software provides full cycle programming—including freezing rate, hold duration, primary drying ramp slope, pressure modulation via automatic valve control, and secondary drying endpoint detection via product temperature trending. Historical runs are timestamped, indexed by operator ID, and stored locally on redundant SSD drives with RAID 1 mirroring. Remote access is enabled via secure Ethernet connection (OPC UA compliant), permitting off-site supervision, alarm notification via SMTP/SNMP, and synchronization with MES/LIMS platforms. Raw sensor data (every 2 seconds) and derived metrics (e.g., residual moisture estimation via comparative pressure rise test) are exportable in ASTM E1447-compliant format for regulatory submission.

Applications

This freeze dryer serves cross-sector R&D and production needs: stabilization of polyphenol-rich black tea powder for instant beverage formulations; preservation of citric acid and limonene in lemon-derived ingredients without Maillard degradation; long-term storage of lactic acid bacteria cultures for synbiotic foods; lyophilization of vaccine adjuvants and monoclonal antibody intermediates; and dehydration of botanical extracts for nutraceutical capsules. Its thermal stability and vacuum fidelity make it equally suitable for lyophilizing hydrogels, aerogels, and porous ceramic precursors in materials science workflows.

FAQ

What is the maximum allowable load volume per cycle?
Up to 200 L of aqueous solution or 1,200 kg of solid material—subject to cake height constraints and mass transfer limitations.
Does the system support automated pressure rise testing (PRT)?
Yes—integrated PRT functionality enables real-time assessment of primary drying endpoint based on chamber pressure differential during isolation hold.
Can shelf temperatures be individually controlled per zone?
No—shelves operate in parallel mode with uniform setpoint; however, thermal mapping confirms ≤1.0 °C inter-shelf variance under loaded conditions.
Is validation documentation provided with delivery?
Standard delivery includes Factory Acceptance Test (FAT) report, material certificates (3.1 EN 10204), and electrical safety compliance (IEC 61000-6-4). Custom IQ/OQ protocols available upon request.
What cooling infrastructure is required?
A dedicated closed-loop cooling water circuit delivering 37 m³/h at 10–25 °C inlet temperature, with minimum 3 bar supply pressure and filtration ≤50 µm.