Freeze Dryer
CONRAD® Freeze Dryer
To many producers of food and beverage products, freeze drying is attractive as it is a gentle process preserving the product's original shape, color, taste, and nutrients.
The drying process
The CONRAD® process is fully automated and requires only minimal staff for continuous operation. All movement and process parameters are carefully controlled, monitored and logged.
The product is prepared, frozen and loaded onto the CONRAD® trays to pass through the Freeze Dryer. Everything is weighed to ensure the correct volume on each tray for perfect freeze drying. The trays are loaded into the dryer through an efficient airlock system to an inlet elevator inside the CONRAD® chamber. When the elevator has a full stack of product trays, the entire stack is pushed into the first drying zone. More stacks follow and in turn pushed through the various subsequent drying zones of the dryer - each adjusted to provide the drying characteristics required. When the trays arrive at the dryer exit elevator they are unloaded, again through an airlock, and the product is emptied from the trays.
The vapor from the freeze drying process is collected on in the special condensers. In order to ensure a continuous process, all CONRAD® Freeze Dryers are equipped with a Continuous De-Icing (CDI) System enabling automatic de-icing of the condensers without any loss of operating vacuum.
The CONRAD® Freeze Dryers is equipped with an internal vapor condenser with built-in de-icing system unique to GEA. Compared with external condenser systems, it not only saves space, it is more reliable, does not cause product loss and it uses less energy and thus ensures the best overall equipment efficiency.
Design details
Heating plates: Are made of anodized aluminium and placed inside the cabinet in order to provide energy for the freeze drying process. Hot water is circulated through the system to secure an efficient heat transfer to the product. This takes place by radiation. The water temperature can be regulated during the freeze drying process to achieve optimal evaporation laps and avoid overheating of the products. By correct loading into the cabinet, the product trays will be placed between the heating plates for optimal heat transfer. Direct contact between product trays and heating plates must be avoided as the heat can damage the product.
Vapor condensers: Installed in the cabinet in order to condense the sublimated water vapor for Continuous De-icing (CDI). When one of the vapor condensers needs de-icing (typically after one hour), the section is sealed off while the other takes over the condensation function. To melt the accumulated ice, 25 ̊ C water vapor (vacuum steam) will be led into the room.
The water vapor will now condense on the cold icy surface of the condenser and thus melt the ice. In order to restore the de-iced condenser to operating condition, any remaining vapor in the condenser chamber must be condensed by cooling it down until the appropriate operating temperature and vacuum conditions have been reached. A direct switch over when the next de-icing cycle is needed can now be performed without any loss of operating vacuum.
Cold store: The empty trays are conveyed back for refilling with frozen products via an externally combined elevator and convey system.
Related Products
RAY® Freeze Dryer
The RAY® batch freeze drying plant is designed for production of small-to-medium-volume products such as instant coffee and tea, freeze dried fruit, vegetables, meat, seafood and prepared meals. It is also available in a fully sanitary design for freeze drying of bacteria, enzymes, and other bioactive products.
CARINE Extractor
The GEA CARINE coffee extractor system has been specifically designed to deliver the highest possible yield while ensuring the preservation of delicate coffee aroma compounds.
RAY® Pilot Plant Freeze Dryer
GEA’s RAY® Pilot Plant (RAY® PP) is a batch-based freeze dryer designed to process general food products such as instant coffee, fruit, vegetables, meat, seafood and pet food, as well as very sensitive products such as lactic acid bacteria, enzymes and lactoferrin.
GEA MicroWet grinding system
GEA has developed a wet grinding technique for adding Roast and Ground (R&G) coffee to coffee extract. The process preserves the coffee flavor and aromas much more effectively than dry grinding and increases your drying capacity. It’s called MicroWet.
GEA Insights
New food tipping point
Alternative proteins are promising – yet still expensive to produce. The usual response is that scaling up will solve this issue. But what if the solution was really about getting better, not just bigger? From more efficient, high-yield processes to upcycling waste heat, engineers are reshaping how we grow food.
A safer way to produce cancer treatments
As anti-cancer drugs become more powerful and complex, GEA is redefining how to safely freeze-dry these life-saving treatments.
Celebrating digital transformation at GEA
Digital transformation at GEA means more than new tools – it’s about bold ideas, customer impact and a culture that values and drives innovation. Meet this year’s GEA Better World Awards Innovation & Digitalization winners who were celebrated for solutions which are shaping the future of our business.
