Tianfeng TF-FZG-30 Industrial-Scale Vacuum Freeze Dryer
| Brand | Tianfeng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | OEM Producer |
| Category | Domestic |
| Model | TF-FZG-30 |
| Instrument Type | Standard Shelf-Type Freeze Dryer |
| Application Scope | Production-Scale |
| Lyophilization Area | 30.1 m² |
| Ultimate Vacuum | ≤ 2.7 Pa |
| Condensate Capacity (24 h) | 600 kg |
| Cold Trap Temperature | ≤ −65 °C |
| Main Unit Dimensions | 7 × 2.5 × 3.6 m |
Overview
The Tianfeng TF-FZG-30 Industrial-Scale Vacuum Freeze Dryer is a GMP-compliant, production-grade lyophilization system engineered for high-throughput, thermally sensitive material preservation—particularly in food processing, nutraceutical manufacturing, and botanical extract stabilization. It operates on the fundamental principle of sublimation: frozen water is removed directly from the solid phase to vapor under deep vacuum and controlled thermal input, preserving structural integrity, volatile compounds, enzymatic activity, and nutritional profile far more effectively than conventional hot-air or spray drying. Designed for continuous batch operation in regulated environments, the TF-FZG-30 integrates a unified chamber–cold trap architecture with front-loading shelf configuration, enabling efficient heat transfer, uniform drying kinetics, and full process traceability. Its 30.1 m² effective shelf area supports large-volume trays or stainless steel trolleys, making it suitable for pilot-to-production scale transition in commercial food and herbal product development.
Key Features
- GMP-aligned construction: Main chamber and shelves fabricated from electropolished AISI 304 stainless steel with mirror-finish interior surfaces; zero dead-leg design and fully drainable geometry to meet hygienic equipment standards (EHEDG Guideline No. 8, ASME BPE-2023).
- Integrated chamber–cold trap layout with rear-mounted condenser; equipped with dual-view observation windows featuring LED illumination for real-time visual monitoring without vacuum break.
- Configurable shelf system: (13 + 1) × 2 shelves (28 total), spacing 77 mm; optional aluminum extrusion shelves (high thermal conductivity, smooth anodized surface) or AISI 304 stainless steel shelves (laser-cut, satin-finished, clean-in-place compatible).
- High-capacity refrigeration: Dual-stage cascade refrigeration system using high-purity R404A/R23 refrigerant blend; achieves ≤ −65 °C cold trap temperature within ≤ 90 minutes from ambient start-up.
- Robust vacuum architecture: Equipped with ULVAC (Edwards) or equivalent high-efficiency oil-sealed rotary vane + roots booster pump combination; delivers stable ≤ 2.7 Pa ultimate pressure across full load conditions.
- Intelligent control platform: Omron CJ2M PLC paired with industrial IPC running proprietary freeze-drying software; supports multi-step program storage (≥ 100 recipes), real-time parameter override, step-jump functionality, and full audit trail logging.
Sample Compatibility & Compliance
The TF-FZG-30 accommodates a broad spectrum of heat-labile matrices including leaf-based botanicals (e.g., green tea, oolong, pu-erh), fruit pulps, vegetable purees, probiotic cultures, enzyme powders, and functional food concentrates. Shelf loading conforms to ISO 22000 and FDA Food Code Annex A requirements for non-porous, corrosion-resistant contact surfaces. All wetted components comply with FDA 21 CFR Part 11 (electronic records/signatures) when configured with user authentication, change control, and electronic signature modules. The system meets CE Machinery Directive 2006/42/EC and complies with ISO 13485:2016 principles where applied to dietary supplement manufacturing. Validation documentation (IQ/OQ/PQ templates) and FAT/SAT protocols are available upon request.
Software & Data Management
The embedded HMI interface provides dual-mode operation—fully automated sequence control or manual parameter adjustment—with synchronized data acquisition at 1-second intervals. Process variables (shelf temperature, chamber pressure, condenser temperature, vacuum rate, time) are logged to internal SSD and exportable via USB or secure FTP to CSV or PDF formats. Optional cloud-enabled remote access (via encrypted Wi-Fi or Ethernet) allows off-site supervision, alarm notification (SMS/email), and historical trend analysis. Audit trails include operator ID, timestamp, parameter changes, and system events—fully compliant with GLP/GMP data integrity expectations per ALCOA+ principles. Data backups are automatically generated daily and retain ≥ 12 months of operational history.
Applications
- Stabilization of polyphenol-rich tea extracts while retaining catechin epimerization profiles and antioxidant capacity (validated per AOAC 2007.01 and ISO 14502-1).
- Production of instant soluble tea granules with reconstitution clarity > 95% and moisture content < 2.5% w/w (ASTM D4457).
- Lyophilization of fermented tea biomass (e.g., kombucha SCOBY) for probiotic viability retention (> 10⁸ CFU/g post-rehydration).
- Preservation of volatile aroma compounds (e.g., linalool, geraniol) in scented teas via low-temperature primary drying (< −25 °C shelf temp) and controlled secondary drying ramp.
- Scale-up support for clinical nutrition formulations, functional mushroom powders, and organic herb blends requiring residual solvent compliance per ICH Q3C.
FAQ
Is the TF-FZG-30 suitable for Good Manufacturing Practice (GMP) environments?
Yes—the unit is constructed to pharmaceutical-grade hygiene standards, includes full electronic record capability, and supports formal validation protocols required for food-grade GMP and dietary supplement cGMP facilities.
Can shelf temperature be independently controlled per layer?
No—shelves operate in uniform thermal zones; however, the system supports gradient-based drying cycles via programmable ramp/soak sequences across the entire shelf stack.
What vacuum pump configurations are supported?
Standard configuration includes ULVAC DS-301B + GXS-1000 booster; alternative options include dry screw pumps (for oil-free operation) or hybrid diffusion/pumping systems upon request.
Does the system support steam sterilization (SIP) or cleaning-in-place (CIP)?
CIP is supported via integrated spray ball manifolds and validated rinse cycles; SIP is not standard but can be implemented as a custom engineering package.
What is the typical lead time for delivery and commissioning?
Standard lead time is 5–7 working days after order confirmation; FAT and on-site SAT support are included for international shipments, subject to local regulatory pre-approval timelines.
