Tianfeng TF-FZG-5 Horizontal Laboratory-Scale Food & Biomaterial Freeze Dryer
| Brand | Tianfeng |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Product Category | Domestic |
| Model | TF-FZG-5 |
| Voltage | 380 V, 50 Hz, 3-Phase, 5-Wire |
| Rated Power | 37 kW |
| Effective Chamber Volume | 50 L |
| Internal Dimensions (L×W×H) | 4500 × 2100 × 3600 mm |
| External Dimensions (L×W×H) | 4500 × 2100 × 3600 mm |
| Shelf Quantity | 5 + 1 radiant shelf |
| Shelf Size | 1000 × 1000 × 20 mm |
| Shelf Spacing | 65 mm |
| Shelf Material | SUS 304 stainless steel |
| Chamber Material | Cylindrical SUS 304, mirror-polished interior |
| Condenser Type | Cylindrical, SUS 304 coil |
| Ultimate Condenser Temperature | –65 °C to –70 °C |
| Chamber Temperature Range | –45 °C to +80 °C |
| Ultimate Vacuum | ≤2.7 × 10⁻² mbar |
| Max Ice Capacity | 100 kg |
| Cooling Water Requirement | 14 m³/hr (P = 1.5–2 bar, T ≤ 25 °C) |
| Defrost Water | ≥0.4 ton/batch (P ≥ 2 bar, T = 80 °C) |
| Compressed Air | 60 L/min (P = 4–8 bar) |
| Control System | Omron PLC + Touchscreen IPC |
| Software | TF-5000 Process Management Suite |
| Compliance | Designed and validated per GMP principles for food and botanical processing |
Overview
The Tianfeng TF-FZG-5 is a horizontal, integrated laboratory-scale freeze dryer engineered for reproducible lyophilization of heat-sensitive biological matrices—including pet food formulations, dairy-based snacks (e.g., yogurt cubes), meat derivatives, herbal extracts, and functional food ingredients. It operates on the fundamental principle of sublimation under controlled low-pressure and cryogenic conditions: frozen water is removed directly from the solid phase to vapor without passing through the liquid state, preserving structural integrity, enzymatic activity, volatile compounds, and nutritional profiles. Unlike conventional dehydration methods, this process minimizes thermal degradation and oxidation—critical for maintaining organoleptic properties, microbiological stability, and shelf-life extension in premium pet nutrition and nutraceutical applications. The unit integrates primary drying (sublimation) and secondary drying (desorption) stages within a single chamber–condenser architecture, eliminating inter-chamber transfer risks and enabling seamless process continuity.
Key Features
- Integrated chamber–cold trap design with rear-mounted cylindrical condenser (SUS 304 coil), achieving ultimate temperatures of –65 °C to –70 °C and ice capacity up to 100 kg per cycle.
- GMP-compliant construction: cylindrical 304 stainless steel chamber with electropolished, mirror-finished interior; zero-weld crevices and sloped drain geometry to prevent microbial harborage.
- Five temperature-controlled shelves plus one upper radiant shelf (1000 × 1000 × 20 mm, 65 mm spacing), all fabricated from brushed 304 stainless steel for uniform heat transfer and cleanability.
- Oil-heated shelf system (no steam required) enables precise, programmable shelf temperature control from –45 °C to +80 °C—supporting both deep pre-freezing and gentle secondary drying.
- Dual-mode defrost system: optional hot gas or steam-assisted defrosting, fully automated and traceable via PLC log, ensuring rapid ice removal and residue-free condenser maintenance.
- Omron PLC-based control architecture with touchscreen industrial PC (TF-5000 software suite), supporting multi-step recipe storage, real-time parameter override, step-jumping, and full audit trail generation.
- Modular vacuum system with ULVAC (Edwards/Airco) high-vacuum pumps, delivering stable base pressure ≤2.7 × 10⁻² mbar—validated for consistent mass transfer kinetics across batch sizes.
Sample Compatibility & Compliance
The TF-FZG-5 accommodates heterogeneous sample formats: bulk trays (up to 50 kg nominal load), stacked pet treat molds, shallow yogurt pans, and extract-loaded vials or pouches. Its wide thermal range and adjustable shelf heating support diverse eutectic behaviors—from low-Tg meat slurries (–25 °C to –30 °C collapse point) to high-sugar dairy matrices (–35 °C to –40 °C). All wetted surfaces meet FDA 21 CFR Part 11 readiness standards for electronic records and signatures when configured with user access control, event logging, and data backup protocols. Design documentation aligns with ISO 9001:2015 and ICH Q5C guidelines for biopharmaceutical process validation—making it suitable for GLP/GMP-aligned R&D environments evaluating stability, reconstitution time, and residual moisture (≤2% w/w typical, verified by Karl Fischer titration).
Software & Data Management
The TF-5000 control software provides full lifecycle process management: recipe creation (temperature ramp rates, hold durations, vacuum setpoints), live trend visualization (shelf temp, chamber pressure, condenser temp), and exportable CSV/Excel logs with timestamps and operator IDs. It supports 21 CFR Part 11 compliance modules including electronic signatures, role-based permissions, and immutable audit trails for all critical parameter changes. Data integrity safeguards include automatic backup to external NAS, encrypted local storage, and configurable alarm thresholds with SMS/email notification integration. Batch reports include metadata such as total cycle time, ice load, energy consumption (kWh), and deviation flags—enabling statistical process control (SPC) and continuous improvement initiatives.
Applications
- Pet food development: freeze-drying raw meat blends, organ meats, and functional supplements while retaining bioactive enzymes (e.g., proteases, amylases) and volatile aromatics.
- Dairy innovation: stabilizing probiotic-rich yogurt cubes and kefir powders without compromising CFU viability (>90% retention demonstrated at –40 °C shelf temp).
- Botanical processing: dehydrating aqueous herbal extracts (e.g., turmeric, echinacea) with minimal flavonoid degradation and no solvent residues.
- Academic & contract research: method development for novel biomaterials (collagen hydrogels, insect protein matrices) requiring precise moisture control and morphology preservation.
- Regulatory pilot studies: generating stability data packages compliant with AAFCO, FEDIAF, and EFSA requirements for shelf-life claims.
FAQ
Does the TF-FZG-5 require external pre-freezing?
No—it includes an integrated shelf pre-freezing function capable of reaching –45 °C, eliminating cross-contamination risks associated with manual transfer from ultra-low temperature freezers.
Can shelf temperature be independently controlled during primary drying?
Yes—the oil-heated system allows dynamic ramping and holding at ±0.5 °C accuracy, synchronized with vacuum feedback to optimize sublimation front progression.
Is validation documentation available for GMP audits?
Yes—Factory Acceptance Test (FAT) and Installation Qualification (IQ) protocols are provided; Operational Qualification (OQ) templates and calibration certificates for PT100 sensors and Pirani gauges are included.
What maintenance intervals are recommended for the vacuum pump and refrigeration system?
Vacuum pump oil change every 2,000 operating hours; refrigerant circuit inspection annually; condenser coil cleaning after every 10–15 batches depending on product load and residual fat content.
Can the system be integrated into a central monitoring network (e.g., SCADA or LabVantage)?
Yes—via Modbus TCP/IP or OPC UA interface; engineering support is available for protocol mapping and secure firewall configuration.
