Issues With Freeze Drying And Their Solutions

When utilising a freeze dryer and freezing it, there is a possibility that certain complications will arise throughout the process. It could have been a problem with the machine itself, or it could have been done by the operator. In the following paragraphs, Vikumer will provide a summary of a few issues that are regularly encountered, along with some probable solutions to those complications. Despite the fact that the freeze-dry machines that you are using are manufactured by a different company, there is no difference in the effectiveness of the solutions.

1. Shape Of Dried Product Was Modified

If you are working with food items that are readily consumable.It was principally the raw ingredients that had been partially frozen in the past that were responsible for the altered shape of the dehydrated outcome. If there is a substantial pressure difference between the inside and exterior of a raw product, there is a risk that the product will burst during the freeze-drying process. This is because the product will be subjected to the freezing process.

It is possible that the lack of water sublimation pathways is another variable. This is something that needs verification. By way of illustration, when blueberries are freeze-dried, water has a tough time penetrating their resistant surface. The lack of moisture in blueberries is the reason behind this. Before beginning the freezing drying process, the skin of the animal must first be damaged in order for the vapour to leave the area.

In the case that you are working with medications, bio samples, or chemicals, you should carry out the following precautions.

For more precise examples, you are required to undertake an inspection of the raw ingredients, components, and concentration rate. This is the first and most important step. In order to successfully initiate the lyophilization process, it is necessary to dilute a significant number of the raw components. This is a prerequisite for the procedure.

After that comes the freezing curve, and then there is the opportunity to monitor the temperature. The shape of the finished product, as well as the amount of time it takes for the product to dry, will be influenced by a number of factors, such as the annealing process, the speed at which the product is frozen, and other factors.

2. The Product Isn't Drying

The first thing that needs to be done is to make sure that the drying chamber has been fitted with the correct climate. The third consideration is in the case that the condensing coils are cold. In the third step, you should investigate whether or not the temperature on the shelves can naturally rise. All of this information may be viewed immediately on the controller screen of a freeze dryer that is utilised on an industrial basis. This is something that is conceivable.

However, despite the fact that the problem is still present, it is acceptable after the elements that were described earlier have been validated. Sensors that have failed to function properly are the most likely source of issues. If, for instance, the heater and fluid pump are running normally but the shelves are not heating up, it is quite probable that the temperature sensor in your freezer dryer is not functioning properly. This is because malfunctioning sensors are more likely to occur. Please be aware that temperature sensors that are not functioning properly are always pre-programmed to read either +100C or +1000C. I just wanted to let you know about this. In the event that the sensor fails, it is essential for it to supply the controller with accurate information in order to avoid the raw materials from being heated for an extended period of time and from being burned.

3. Carbonisation Of Products

Because you suggested freezing the material at a temperature that was far higher than the actual temperature. In order to complete the process of vacuum freeze drying, a considerable amount of time is necessary. In the case that it is necessary, there are references to the use of the thermal energy supply in order to raise the temperature on the shelves. Both of these concepts are discussed. In the event that an excessive quantity of heat is supplied to the raw material in a length of time that is sufficiently short, it is possible that the raw material could melt. Consequently, this would result in the outcome becoming warped and causing it to burn.

4. The Drying Chamber Pressure Doesn't Drop To A Set Value

In order to find a solution to this problem, it is necessary to investigate two distinct aspects. In the event that the oil in the vacuum pumps is worn out or damaged, one of the first things that should be done is to replace it. Additionally, it is essential to make certain that the door and the valves have been completely closed.

It is essential that you are aware that the oil that is used in the hoover pump ought to be clear and transparent; if it appears to be milky, it ought to be replaced as soon as possible. In the event that it does not, it will not be useful to itself, and it will be unable to establish an environment in an effective manner.

5. Abnormal Condenser Temperature

The expansion of the coolant is what causes the compressor system to immediately cool the condenser. This is accomplished by the fact that the coolant expands. As a result of this, you are required to carry out a comprehensive check of the compressor system in order to determine whether the H/L/M/O pressure is within the usual range or whether there is a leak in the coolant.

6. The Freeze Drying Recipe Is Not Automated

There are two distinct modes of operation that freeze dryers can take. both fully and partially automated for the relevant purposes. It is only able to function automatically when it is in the freeze drying phase, which entails ending and then starting again automatically until the drying process is finished. This is the only time it is able to function automatically automatically.

A variety of problems are associated with freeze drying, as was briefly described above. Freezing dryers that are predominantly utilised on a production scale should be considered. It would be greatly appreciated if you could send us an email in the event that you are unable to locate the answers; we would be pleased to react to your inquiry and even add to what has already been expressed.