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FD Series Vacuum Freeze Dryer Fruit Lyophilizer Liofilizator

Parameters Heating Area(m2):50-800m2/h Temperature Adjustment Range(℃):30-120℃ The Vacuum Freeze Dryer represents a sophisticated dehydration technology that employs a combination of multidisciplinary development methods such as refrigeration, heating, vacuum, biological, electrical, and more. This process freezes hydrous materials at low temperatures and subsequently utilizes a thermal radiation technique to heat them under vacuum conditions, thereby sublimating ice directly into gas. Once the moisture has been removed, an ice-condenser (cold trap) and vacuum device are employed to dehydrate the remaining water content.

key word:

FD Series Vacuum Freeze Dryer

Fruit Lyophilizer

Liofilizator

Product details

Brief Introduction

The Vacuum Freeze Dryer represents a sophisticated dehydration technology that employs a combination of multidisciplinary development methods such as refrigeration, heating, vacuum, biological, electrical, and more. This process freezes hydrous materials at low temperatures and subsequently utilizes a thermal radiation technique to heat them under vacuum conditions, thereby sublimating ice directly into gas. Once the moisture has been removed, an ice-condenser (cold trap) and vacuum device are employed to dehydrate the remaining water content.

 

Equipment Characteristics

The KFD series vacuum freeze dryer comprises of several subsystems, namely the material quick freezing system, vacuum tank system, heating system, vacuum system, refrigeration system, material transfer system, electric control system, pneumatic system, and disinfection system. The overall system is optimized with a reasonable, economic and advanced design, and is highly efficient, automated, energy-saving, easy to operate, and convenient to maintain.

The vacuum system employs a combination of water ring pump or oil seal pump with multi-stage roots pump to remove air quickly and maintain vacuum conditions with small power, thus reducing energy consumption. The water ring pump eliminates water content and overcomes the disadvantages of the oil seal pump's poor drainage performance, oil emulsification, and vacuum instability.

The heating system utilizes a sealed water circulation system with an automatic compression function and a 3-way regulated valve to adjust the heat of the water circulation system. The automatic compression system can guarantee hot water temperature up to +120°C, which increases the thermal efficiency.

The refrigeration system uses Freon refrigeration for small to medium-sized models and ammonia single-phase circulation refrigeration for large models. The expansion valve automatically adjusts the liquid flow, while the ice-condenser applies a postposition type cold trap with short pipes connection, little resistance, and smooth moisture and gas access. The water catch is efficient, energy-saving, and even.

The electric control system employs intelligent instruments and a PLC system with touch screen control and computer monitoring. It features an automatic control system with ten-time periods control for the freeze-drying curve, specialized for food lyophilization. The system allows for easy and convenient curve parameter setting, high reliability, and good accuracy. It also has the function of storing and querying historical data, facilitating production process analysis.

 

Summary Of Vacuum Freeze Drying

Vacuum freeze drying is a state-of-the-art dehydration technology that involves freezing hydrous material at low temperatures, and then using thermal radiation to heat it under vacuum conditions, thereby sublimating ice directly into gas. After removing the moisture, it employs an ice-condenser (cold trap) and vacuum device to dehydrate the remaining water content. This is a combined application technology based on multidisciplinary development, including refrigeration, heating, vacuum, biological, electrical, and more.

Vacuum freeze drying technology has a wide range of applications, including chemical products, biologics, health products, herbs, and agricultural products such as meat, poultry, eggs, seafood, vegetables, fruits, and more.

 

Vacuum Freeze Drying Process

The vacuum freeze drying process can be broken down into three main stages.
1. The first stage is the quick freezing of the material. During this stage, the water content in the products turns into a solid state from a liquid state by freezing. The final frozen temperature should be below the eutectic point temperature, which is determined by testing the material to ensure that it is fully frozen. The freezing speed of the material depends on its characteristics, and a quick blast freezing room is used for pre-freezing.

2. The second stage is the primary dehydration stage, also known as the sublimation dehydration stage. The frozen material with a temperature below the eutectic point is dehydrated in a vacuum condition by sublimation to remove its moisture. During sublimation, the heating plate temperature and vacuum condition must be strictly controlled to prevent the material from melting or the temperature from rising above the eutectic point. The temperature of the dried parts must also be prevented from rising above their disintegration temperature, which can cause a change in shape or even collapse. During this stage, the heating plates heat the material by thermal radiation or provide the energy for sublimation. The vacuum tank must be under vacuum condition, and the ice-condenser (cold trap) catches the moisture that comes from the material and condenses it to ice on the surface of the cold trap coils.

3. The third stage is the secondary dehydration stage, also known as desorption drying. The purpose of this stage is to remove bound moisture. Because the adsorption energy of bound moisture is very high, a large amount of heat energy must be provided in this stage. This means that the heating plate temperature will be slightly higher to approach the highest temperature that the material can bear. When the material moisture is within the specified range, the final dehydration is complete.

4. To determine whether the vacuum freeze drying process is complete, it can be based on experience of the material temperature curve, sample status, shape, and other factors. The process can also be evaluated using terminal point testing, such as air pressure increases.

 

Equiment Features

The FD Series vacuum freeze dryer consists of various components, including a material quick freezing system, a vacuum tank system, a heating system, a vacuum system, a refrigeration system, a material transfer system, an electric control system, a pneumatic system, and a disinfection system. The machine system is designed with optimization in mind, and features a reasonable, advanced, and economic design that allows for high efficiency, high automation, low energy consumption, easy operation, and convenient maintenance.
1. The complete machinery system is strategically deployed with a rational, cost-effective, and advanced design. It operates with high efficiency, a high degree of automation, low energy consumption, and is easy to operate and maintain.

2. The vacuum system is equipped with either a water ring pump or an oil seal pump combined with a multi-stage roots pump. Initially, an oil seal pump with high power is used to quickly remove air, and then a roots pump is used to maintain the vacuum condition with low power consumption, reducing energy usage. Additionally, the water ring pump can remove any water content, preventing the oil seal pump's disadvantage of poor drainage performance, moisture leading to oil emulsification and metamorphism, and vacuum instability.

3. The heating system utilizes a sealed water circulation system that has an automatic compression function. It is equipped with a 3-way regulated valve that controls the heat of the water circulation system. The automatic compression system ensures that the hot water temperature reaches up to +120℃, which enhances the system's thermal efficiency.

4. The refrigeration system uses Freon refrigeration for small to medium-sized models, with an automatic expansion valve that adjusts the liquid flow. For large models, it utilizes ammonia single-phase circulation refrigeration, which provides stable and easy-to-operate refrigeration liquid supply. The ice-condenser adopts a postposition type cold trap, with short pipe connections and little resistance. This allows for smooth access to moisture and gas, with even water catch and efficient, energy-saving performance.

5. The electric control system utilizes intelligent instruments and a PLC system, with touch screen control and computer monitoring. To achieve optimal freeze drying curve control, an automatic control system with 10 time periods specifically designed for food lyophilization has been developed. This allows for easier and more convenient setting of curve parameters, as well as providing high reliability and accuracy. Additionally, the system has a historical data storage and query function, making it convenient for production process analysis.

 

Applications

Vacuum freeze dryer technology has a wide range of applications, including chemical products, biologics, health products, herbs, and agricultural products such as meat, poultry, eggs, seafood, vegetables, and fruits.

 

Specifications

Model KFD-5 KFD-10 KFD-25 KFD-50 KFD-100 KFD-150 KFD-200
Drying Area(m²) 5 10 25 50 100 150 200
Equipment Floor Area (m2) 12 24 50 86 130 190 260
Advise Minimum Usable Area (m2) 22 45 80 180 255 330 450
Size Of Material Tray(mm) 780×540×30 540×645×30 540×645×30 540×645×30 540×645×30 540×645×30 540×645×30
Number Of Material Tray(pcs) 12 24 72 144 288 438 576
Size Of Tank(m) Ф1.0×3.4 Ф1.5×3.2 Ф1.88×4.2 Ф2.0×8.16
Ф2.4×10.2
Ф2.4×13.9 Ф2.4×17.8
Operation Vacuum(Pa) 13.3-133 Pa 13.3-133 Pa 13.3-133 Pa 13.3-133 Pa 13.3-133 Pa 13.3-133 Pa 13.3-133 Pa
Heating Plate Temp.(℃) Normal temperature~+120℃ Normal temperature~+120℃ Normal temperature~+120℃ Normal temperature~+120℃ Normal temperature~+120℃ Normal temperature~+120℃ Normal temperature~+120℃
Electric Heating(Kw) 12 21 50 / / / /
Steam Consumption(kg/h0.7mPa) / / / 150 300 450 560
Cold Load Consumption(kw) 12 22 45 90 180 270 360
Installation Power(Kw) 22 53 112 213 289 370  

Technical description:
1. The FD series freeze dryer has the option of rear-mounted, side-mounted, or top-mounted cold trap positions.
2. Different defrosting methods are available, including one-time water defrosting, steam defrosting, and automatic alternated defrosting.
3. The size of the freeze dryer varies according to capacity, including mini lab, medium production, and large-scale production types. Custom sizes are also available.
4. The FD series freeze dryer uses two heating methods: electric heating for mini and medium-size models, and steam heating for large-scale models.
5. The refrigeration system of the FD series freeze dryer uses either Freon or Ammonia. The table specifies the parameters for Freon refrigeration systems.
6. It is recommended to have a minimum usable area that includes equipment floor area, equipment maintenance space, and processing materials flow area. Multiple sets of equipment can save space and be designed according to specific needs.

 

Processing

Here are the advantages of vacuum freeze drying technology compared to other drying methods:

1. Preservation of Protein: Vacuum freeze drying is a dehydration process carried out at low temperatures which helps in preserving proteins and other heat-sensitive compounds. In comparison to other drying methods, vacuum freeze drying is less likely to cause damage to the protein structure of the material being dried.

2. Minimal Nutrient Loss: Since vacuum freeze drying is carried out at low temperatures, there is very little nutrient loss during the drying process. This helps to preserve the nutritional value of the material being dried.

3. Preservation of Original Features: The low temperature and vacuum conditions during the drying process prevent the growth of microorganisms and the action of enzymes, which helps to preserve the original features of the material.

4. No Change in Shape or Volume: Vacuum freeze drying preserves the original shape and volume of the material, and the final product is porous, not shrunken. This makes the material easy to rehydrate, as it regains its original shape quickly.

5. Protection Against Oxidation: The low oxygen content during vacuum freeze drying helps to protect the material against oxidation.

6. Longer Shelf Life: Vacuum freeze drying removes 95%~99.5% of the moisture from the material, resulting in a final product with a longer shelf life compared to other drying methods.

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