Tianfeng TF-FZG-20 Industrial-Scale Freeze Dryer with 20 m² Shelf Area

Overview

The Tianfeng TF-FZG-20 is an industrial-scale, shelf-type freeze dryer engineered for reproducible, scalable lyophilization of heat-sensitive food matrices—including goji berries, fruits, vegetables, herbal extracts, functional foods, and pet nutrition products. It operates on the fundamental principles of sublimation under deep vacuum: frozen water is removed directly from the solid phase to vapor without passing through the liquid state, preserving structural integrity, volatile compounds, enzymatic activity, and nutritional profile. The unit integrates a front-chamber/rear-condenser monoblock architecture, minimizing footprint while maximizing thermal and vacuum efficiency. Its 20 m² shelf area supports batch processing of up to 200 kg of loaded material—positioning it between laboratory pilot systems and full commercial production lines. Designed for continuous operation in regulated food manufacturing environments, the TF-FZG-20 meets foundational hygienic design criteria aligned with FDA Food Code Annex A, EHEDG Guideline Doc. 8, and ISO 22000 hygiene requirements.

Key Features

• Monolithic chamber–condenser structure with cylindrical stainless-steel construction (SUS 304), mirror-finished interior surfaces (Ra ≤ 0.4 µm), and zero-hygiene-dead-zone geometry for CIP/SIP compatibility.
• 11-shelf configuration (10 active + 1 temperature-compensated shelf) with precision-machined aluminum or electropolished SUS 304 options—optimized for uniform heat transfer and rapid thermal response.
• High-capacity condenser operating at ≤ −65 °C, equipped with clean-grade SUS 304 coil tubing and configurable as either integrated or modular assembly based on facility layout constraints.
• Robust refrigeration system built with premium imported compressors, low-GWP refrigerants, and redundant cooling water interface (25 m³/hr @ ≤25 °C inlet temp) ensuring stable shelf temperature control across −45 °C to +80 °C range.
• Omron CP1E-N60DT-D PLC controller with real-time Ethernet communication, audit-trail-enabled TFD-5000 software platform supporting multi-step recipe programming, in-process parameter override, and step-jump functionality.
• Full-vacuum performance validated to ≤ 2.7 Pa using high-efficiency vacuum pump train incorporating ULVAC (formerly Unisys) technology—compliant with ISO 27893:2017 vacuum integrity standards.

Sample Compatibility & Compliance

The TF-FZG-20 accommodates standard 304 stainless-steel trays (600 × 400 mm or custom sizes), aluminum pans, and perforated polymer carriers suitable for whole fruits, sliced produce, powdered botanicals, and extruded pet treats. Its chamber geometry and shelf loading protocol support both static and intermittent shelf movement configurations. All wetted surfaces conform to FDA 21 CFR 178.3570 (indirect food additives) and EU Regulation (EC) No. 1935/2004. While not certified for pharmaceutical GMP (Annex 1), its mechanical design, documentation package, and validation support services meet baseline requirements for food-grade process qualification under HACCP, BRCGS Food Safety Issue 9, and SQF Edition 9. Optional IQ/OQ documentation packages are available upon request.

Software & Data Management

The TFD-5000 control suite runs on an embedded industrial PC with resistive touchscreen interface, offering full recipe management (≥ 100 stored protocols), real-time trend logging (temperature, pressure, condenser load), and CSV export via USB or network share. All critical process events—including vacuum break, shelf heating activation, and defrost initiation—are timestamped and recorded with operator ID. The system supports optional 21 CFR Part 11 compliance modules (electronic signatures, role-based access, audit trail encryption) when deployed in regulated nutraceutical or clinical trial supply environments. Firmware updates are distributed free-of-charge and installed via secure OTA protocol or local media.

Applications

This system is routinely deployed for: primary drying of goji berry pulp and whole berries while retaining anthocyanin content and rehydration kinetics; stabilization of enzymatically active fruit powders (e.g., pineapple bromelain, papaya papain); low-temperature dehydration of probiotic-enriched pet snacks without viability loss; production of instant soluble coffee and tea granules with minimized Maillard degradation; and preservation of delicate botanical actives (e.g., ginsenosides, curcuminoids) prior to encapsulation. Its thermal stability and vacuum repeatability make it suitable for DOE-driven process optimization studies and scale-up correlation modeling per ASTM F2372-22.

FAQ

Is the TF-FZG-20 compliant with current Good Manufacturing Practice (cGMP) for food production?
Yes—the equipment is constructed to GMP-aligned hygienic design principles, including weld-seam polishing, drainage angles ≥ 3°, and absence of crevices. Full cGMP certification requires site-specific validation, which Tianfeng supports via qualified engineers.
Can shelf temperature be controlled independently per layer?
No—shelves operate in parallel mode with single-loop PID control. However, the +1 temperature-compensated shelf mitigates edge effects during large-batch loading.
What vacuum pump configurations are supported?
Standard delivery includes ULVAC DS series oil-lubricated rotary vane pumps. Optional dry scroll or hybrid pump trains are available for solvent recovery or oil-free operation.
Does the system support automated cleaning-in-place (CIP)?
The chamber and condenser are CIP-ready with dedicated spray ball ports and drain slope verification. Integration with plant CIP skids requires engineering coordination.
Is remote monitoring available?
Yes—via Modbus TCP or OPC UA interface. Secure cloud telemetry (with customer-owned AWS/Azure instance) can be enabled through optional gateway hardware.