The Principles Of Freeze Drying: Why Accurate Hoover Technology Is Important

Freeze drying, sometimes referred to as lyophilization, is a popular preservation technique used in a wide range of items, from the instant coffee in our morning brew to the fresh herbs and veggies that top store-bought pizzas. Pharmaceuticals is another industry that uses this idea, especially when producing expensive, delicate injectable medications. Since many pharmaceutical goods are heat-sensitive, it is obviously advantageous to be able to dry contents at low temperatures.

A key component of the lyophilization process is vacuum technology. Following the initial freezing of the items, the pressure is gradually decreased using a vacuum until sublimation occurs. During the first drying phase, the majority of the moisture is eliminated. After the desired amount of residual moisture has been removed through secondary drying, the item is sealed in a moisture-free container.

Four essential parts are needed to build a sturdy drying system for lyophilization: mass spectrometers, vacuum pumps, pressure gauges and leak detectors. With superior alternatives for each of the aforementioned, Pfeiffer Vacuum's extensive portfolio of technologies streamlines procurement by providing a multitude of solutions from a single source.

Production Of Hoover

Strong vacuum pumps are needed for freeze drying. While even lower pressures would be needed for the last stage, most drying occurs at pressures between 0.5 hPa and 10-2 hPa. Achieving the required pump-down time requires high pumping speeds. Meanwhile, a dependable, low-maintenance vacuum pump is necessary because of the long sublimation period.

For many years, rotary vane pumps have been the industry standard because of their inexpensive initial cost, sturdy design, and high end pressure. Pfeiffer Vacuum's DuoLine and HenaLine pumps are two examples. Even better, the wear-free magnetic coupling option for the small DuoLine system removes the possibility of oil leakage.

Although rotary vane pumps lubricated with oil are still a common option, dry compressing options—which can even be combined—are becoming more and more popular. For instance, screw and root pumps are frequently used in conjunction during the coffee drying process. These pump designs allow for extended working hours with fewer oil changes because no lubricant can mix with the pushed gases. Customers will benefit from reduced ownership costs and increased cleanliness as a result of this.

Pfeiffer Vacuum offers two dry compression pumps: the OktaLine roots pump and the HeptaDry screw pump, which is distinguished by its fast pumping speed and optimal temperature profile. Additionally, the business sells HiLobe roots pumps, which are an improvement over OktaLine roots pumps that use a frequency inverter and a cutting-edge drive idea to provide strong pump-down performance and low operating costs.

Monitoring Of Pressure

To ensure constant product quality, the drying chamber's pressure and temperature must be strictly regulated. For this, very precise pressure gauges are needed. Pirani and capacitance gauge technologies are taken into account while controlling the freeze-drying process since they span the pressure range that is important for the operation.

The more affordable alternative is the Pirani gauge, which may reach a workable precision of 10 to 10-3 hPa. The type of gas being utilised determines these gauges. Pfeiffer Vacuum's Pirani gauges use a special Pulse technology that increases their accuracy. However, capacitive vacuum gauges that measure independent of gas type and have a maximum measuring range of either 1 hPa or 10 hPa generally perform better.

Pfeiffer Vacuum offers both capacitive and Pirani gauges in their product line. Sometimes these products are mixed together in a procedure called comparative pressure measurement, which is a useful way to figure out how much vapour is in the drying chamber. For example, a Pirani gauge calibrated for nitrogen will display a significantly greater pressure for vapour. Operators can precisely determine the water vapour content by comparing the observed values obtained from the simultaneous capacitive gauge measurement.

Any pressure gauge's accuracy and repeatability must be guaranteed by routine calibration. Customers can obtain external calibration services from Pfeiffer Vacuum in compliance with strict industry requirements. As an alternative, the business offers calibration pumping stations for on-site correction. For clients calibrating a large number of gauges, this may be more economical.

Process Gas Observation

Comprehensive documentation of the freeze-drying process is made possible by mass spectrometers. Additionally, by spotting silicone oil leaks, they are essential to quality control. Furthermore, the vapour concentration in the drying chamber is monitored using mass spectrometers such as Pfeiffer Vacuum's PrismaPro, which helps producers establish an extremely precise endpoint for the primary and subsequent drying stages.

One crucial and adaptable technology for lyophilization is mass spectrometry. Batch monitoring can be done manually or fully automatically, and Pfeiffer Vacuum has the knowledge and resources to incorporate this crucial technology into your workflow.

Leak Detection

It is impossible to overstate the significance of leak detection in the creation of a reliable drying system. First off, the system's general "tightness" will have an impact on its capacity to generate the required pressure levels. It is imperative to safeguard items from microbiological contamination, particularly in the context of aseptic freeze drying of pharmaceuticals.

Another field in which Pfeiffer Vacuum excels is leak detection. For this application, the pressure rise approach is suggested by the company as a suitable option. Manufacturers can locate leaks quickly and efficiently by using the widely applicable ASM 340. The ASM 310 is a transportable version of the technology that is more smaller.

Solutions For Lyophilization From A Single Source

For the purpose of constructing a drying system that is capable of preserving food, beverages, and drugs, it is required to have a wide range of technological components. Pumps, gauges, calibration tools, mass spectrometers, and leak detectors are some of the components that are included in this category. In addition to providing technical training, dependable service, and trustworthy guidance, Pfeiffer Vacuum offers any and all of the services that have been described above.If you are interested in gaining a deeper understanding of the relevance of accurate pressure monitoring in the process of lyophilization, you may view the webinar that is provided via the link that is provided below.