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Freeze-drying technology - Yupinyan Biology provides freeze-drying technology research and development - processing freeze-drying and other businesses

2025-07-08

      Freeze-drying technology, one of the ways to keep substances from spoiling and deteriorating, is to pre-cool and freeze substances containing a lot of moisture into solids, and then sublimate the solid water directly under vacuum conditions, while the substance itself remains frozen
ice shelf
Medium, so its volume remains unchanged after drying. Solid water absorbs heat during sublimation, causing the temperature of the product itself to drop and slowing down the sublimation speed. In order to increase the sublimation speed, shorten
drying time
, the product must be properly heated. The entire drying is carried out at a lower temperature.

advantage

Freeze drying is carried out at low temperatures, so it is particularly suitable for many heat-sensitive substances. Such as
protein
Microorganisms and the like do not undergo denaturation or lose biological vitality. Therefore, they are widely used in medicine.
When dried at low temperatures, some of the substances
volatility
The loss of ingredients is minimal, making it suitable for drying some chemical products, medicines, and foods.
During the freeze-drying process, the growth of microorganisms and the role of enzymes cannot be carried out, so the original properties can be maintained.
Fourth, due to drying in a frozen state, the volume remains almost unchanged, maintaining the original structure, and no concentration occurs.
After drying, the material dissolves rapidly and completely after adding water, and returns to its original state almost immediately.
Due to the fact that drying is carried out under vacuum, there is very little oxygen, so some easily oxidized substances are protected.
Drying can remove more than 95-99% of the moisture, allowing the product to be stored for a long time without deterioration.
Therefore, freeze-drying is
Pharmaceutical industry
，
Food industry
It is widely used in scientific research and other fields.

application

The freeze-drying of the product needs to be carried out in a certain device, which is called
Vacuum freeze dryer
, short name
freeze dryer
。
The freeze dryer is divided according to the system, by
Refrigeration system
Vacuum system,
Heating system
And the control system is composed of four main parts. According to the structure, it is divided into lyophilized boxes or called
Drying oven
Condenser or water vapor condenser,
Freezer
Vacuum pumps and valves, electrical
control element
And other components.
The lyophilized box is a one that can be cooled to about -40 ° C and heated to about + 50 ° C
High and low temperature box
It is also an able
cut
Vacuum airtight container. It is the main part of the lyophilizer. The products that need to be lyophilized are placed on the layered metal plate layer in the box, frozen, and heated under vacuum to sublimate and dry the moisture in the product.
condenser
It is also a vacuum sealed container with a large surface area of metal adsorption surface inside. The temperature of the adsorption surface can be reduced to below -40 ° C and can be maintained at this low temperature. The function of the condenser is to sublimate the products in the lyophilized box.
water vapor
Frozen adsorption on its metal surface.
The freeze-drying tank, condenser, vacuum pipes and valves, together with the vacuum pump, form the
freeze dryer
Vacuum system. vacuum
System requirements
There is no air leakage, and the vacuum pump is an important part of the vacuum system to establish a vacuum. The vacuum system is essential for the rapid sublimation and drying of the product.
Refrigeration system
by
Freezer
It is composed of pipes inside the lyophilization box and the condenser. The freezer can be two sets independent of each other, or it can be used in combination. The function of the freezer is to
condenser
Refrigeration is carried out to generate and maintain the low temperatures required for their operation. There are two methods of direct refrigeration and indirect refrigeration.
Heating systems for different
freeze dryer
There are different heating methods. Some use direct
Electric heating method
Some use an intermediate medium for heating, and a pump circulates the intermediate medium continuously. The function of the heating system is to heat the product in the lyophilized box to make the moisture in the product continuously sublimate and meet the specified residual moisture requirements.
The control system consists of various
Control switch
, instruct
Adjusting instrument
(See Figure 1) and some
automatic device
And other components, it can be relatively simple, or it can be very complicated. general
degree of automation
The higher freeze-drying machine has a more complex control system. The function of the control system is to manually or automatically control the freeze-drying machine and operate the machine normally to freeze-dry the required product.
The freeze-drying procedure is as follows: before lyophilization, the products that need to be lyophilized are divided into suitable containers, usually glass bottles or
ampoule
, the loading volume should be uniform, the evaporation surface should be as large as possible and the thickness should be as thin as possible; then put it into a metal plate suitable for the size of the lyophilized box. Before packing, cool the lyophilized box empty, and then put the product into the lyophilized box for pre-freezing. Before vacuuming, according to
condenser
Freezer
The cooling speed is advanced to make the condenser work. When vacuuming, the condenser should reach a temperature of about -40 ° C
vacuum
After reaching a certain value (usually a vacuum degree above 100uHg), the product in the box can be heated. Generally, heating is carried out in two steps, and the first step of heating does not make the temperature of the product exceed
eutectic point
The temperature; after the moisture in the product is basically dry, the second step of heating can be carried out, and the product can be quickly raised at this time
maximum temperature
After maintaining the highest temperature for a few hours, the lyophilization can be completed. And the amount of the product in each bottle, the total amount,
Glass container
The shape, specification, type of product, lyophilization curve, and performance of the machine are relevant.
After lyophilization, put dry and sterile air in
Drying oven
Then plug and seal as soon as possible to prevent re-absorption of moisture in the air.

During the freeze-drying process, the temperature of the product and the plate layer,
condenser
Temperature and
vacuum
Curve against time, called
lyophilization curve
Generally, temperature is used as the ordinate and time is the abscissa. Freeze-dried different products use different lyophilization curves. When different lyophilization curves are used for the same product, the quality of the product is also different, and the lyophilization curve is still the same as that of
freeze dryer
Therefore, different products and different lyophilizers apply different lyophilization curves.

Wuhan Yupinyan Bio is deeply involved in the field of freeze-drying technology, focusing on providing professional freeze-drying technology research and development and processing services. Relying on the core principle of freeze-drying - pre-freezing substances containing a lot of moisture into solids, the solid water is directly sublimated in a vacuum environment, and the sublimation efficiency is improved through precise heating. The characteristics of low temperature operation throughout the process can maximize the retention of the original properties and activities of the substance. The service gives full play to the seven core advantages of lyophilization technology: adapting to heat-sensitive substances to avoid protein, microbial and other deactivation; reducing the loss of volatile components, protecting the original ingredients and flavor of the product; inhibiting the growth of microorganisms and enzymes, maintaining the natural properties of the material; after drying, the volume and structure remain unchanged, and there is no concentration phenomenon; excellent rehydration, which can quickly restore the original state after adding water; vacuum environment isolates oxygen, effectively protecting easily oxidized substances; can remove more than 95% -99% moisture, ensuring that the product is stored at room temperature for a long time without deterioration. With its mature freeze-drying equipment system (covering refrigeration, vacuum, heating, and control systems) and customized freeze-drying curve design, Wuhan Yupinyan Bio can provide efficient and accurate freeze-drying technology solutions for products in various fields such as medicine, food, and scientific research. From technology research and development to large-scale processing, it fully meets customers' core needs for product stability, activity retention, and long-term storage.