幅広い用途に対応したパイロットプラントの凍結乾燥
今日の消費者は、準備しやすく、味が良く、新鮮さが長く保たれる食品を積極的に求めています。凍結乾燥は、メーカーが製品の自然な色、特性、一貫性、およびその構成物であるタンパク質とビタミンを保存することによって、これらの要求を満たすことを可能にします。
魚、果物、ハーブなどを含む食品加工のほぼすべての分野に大きなメリットを提供する RAY® 凍結乾燥技術は、高品質なソリューションを実現します。冷凍製品を真空下で乾燥し、製品に内在する溶剤が蒸気として除去されることを保証します。
Key advantages of small-scale freeze drying
The RAY® Plus Pilot Plant offers the following economic and technical advantages:
- Full scalability to industrial systems
- Preservation of product structure and size, as well as key attributes such as color and nutrients
- Flexible operation with variable parameter for product temperature, vacuum and heat input
- Online control and monitoring of vacuum, sublimation rate, heating plate temperature and product temperature.
- Batch reporting and recipe system integrated
- High throughput and large capacity condenser
- Automatic generation of freeze drying profile.
GEA RAY® パイロットプラント凍結乾燥機の主な特長
タッチスクリーンを介して操作できる RAY® パイロットプラントは、衛生的な処理を実現することを目的に設計されているため、洗浄や維持管理が簡単です。製品がチャンバー内に配置されると、その処理は全自動で実行され、製品温度、加熱プロファイル、重量損失などの重要なすべてのパラメータが監視、保存され、完全なドキュメントを提供し、再現性が確保されます。RAY® パイロットプラントは、乾燥プロファイルを自動生成するだけでなく、製品の最高温度や、一定の重量、温度、真空差などの要因に基づいて、処理の終了の時点や状態を決定することもできます。
RAY® パイロットプラントは0.2 mbarで動作する設計ですが、0.1 mbarまでの低圧にも耐えることができます。さらに、RAY® のコンセプトは、迅速な排気時間、効果的な除氷、効率的なトレーのローディングによって、バッチ間のダウンタイムを短く抑えられます。パイロットプラントには次の 2 つのサイズがあります。
| RAY® パイロットプラント | RAY® 1 | RAY® 2 |
| 乾燥面積 (m²) | 0.7 | 1.5 |
| 負荷 (kg/day) | 20 | 38 |
| 乾物 (%) | 20.0 | 20.0 |
| 予測バッチ時間 (h) | 8.0 | 8.0 |
| 昇華 (kg H2O/日) | 15.3 | 30 |
| 生産高 (kg/日) | 4.0 | 8.0 |
| 設置電力 (kW) | 12 | 25 |
| 平均電力消費量 (Kwh/h) | 7 | 12 |
| 水消費量 (L/h) | 50 | 75 |
RAY® Plus Pilot Plant freeze dryer at a glance
| Cabinet and condenser | Stainless steel |
|---|---|
| Installation | Plug and play unit that only requires cold water and power |
| Vapor trap | High capacity, handles sublimation of 2.5 kg H₂O/m²/h |
| Heating | Water-based system, controlled heating and cooling from 20 to 140 °C. Radiation heating for even heat input |
| Evacuation | To 1 mbar in less than 6 minutes |
| Vacuum regulation | Accurate from 0.1 to 2 mbar for controlled drying. Designed to operate at 0.3 mbar |
| Monitoring | Product, heating plate, condenser temperature and pressure control, monitoring and logging. Product weighing system |
| Control | Touchscreen computer-based HMI |
The two sizes compared
| RAY® Plus Pilot Plant | Model RAY®1 Plus | Model RAY®2 Plus |
|---|---|---|
| Drying surface (m²) | 0.76 | 1.5 |
| Load (kg/day) | 2x12 | 2x24 |
| Dry matter (%) | 20.0 | 20.0 |
| Expected batch time (h) | 10-12 | 10-12 |
| Sublimation (kg H₂O/day) | 19 | 38 |
| Production (kg/day) | 5 | 10 |
| Installed power (kW) | 12 | 25 |
| Average consumption (kWh/h) | 7 | 12 |
| Water consumption (L/h) | 200 | 300 |
How freeze drying validation works on a pilot plant
The main purpose of the pilot plant is to produce small samples similar to full production samples. Furthermore, the pilot plant will generate the recipe before you size a line. On the RAY® Plus Pilot Plant all vital parameters, such as product temperature, heating profile and loss of weight are controlled, monitored and stored to provide full documentation and ensure repeatability. The unit can generate the drying profile automatically and determine the end point of the process from maximum product temperature and/or factors such as constant weight, heating plate temperature and vacuum. The RAY® Plus Pilot Plant offers full scalability to industrial systems, such as GEA’s RAY® batch freeze dryers. The newest, RAY® Plus, is designed for high-capacity, automated production. Following a validation run at the GEA drying test center in Copenhagen, you will receive freeze-dried product samples and a detailed report.
Test center trials and pilot plant rental
Trials at the GEA test center
At the GEA drying test center in Copenhagen, Denmark, you can work with our experts to evaluate your processes, test new recipes and configure the best GEA system for your needs. We have carried out more than 3,000 tests and worked with about 1,000 product types. Whether you are new to freeze drying or looking to upgrade, expand or diversify your production, we take the time to understand your challenges and objectives and help identify the best solution for your business.
One of the most effective ways to optimize your product for freeze drying, both in terms of product quality and production capacity, is through testing at the GEA test center. Typically, you supply frozen raw material, and GEA performs tests at three different parameter settings, resulting in three product qualities produced at three different capacities. You can then evaluate the results and select the preferred product quality and the corresponding capacity.
From the test work, you will receive the three freeze-dried samples and a detailed report covering all important test parameters and trends, together with an estimated capacity for an industrial plant for each sample.
To learn more about validation testing or to arrange a trial at the GEA drying test center in Copenhagen, please submit an enquiry here.
Rent pilot equipment for development on your own site
We offer rental pilot equipment, the GEA RAY®1 Plus, for on-site development, with a freeze-drying process specialist ensuring seamless startup and staff training. The training includes classroom instruction in freeze drying, product optimization and freeze dryer operation, as well as practical on-site training using your actual product. Typically, the training includes three test runs with different process parameters, similar to the testing carried out by GEA at the GEA test center.
If you only have one product, the best option is typically to conduct tests at the GEA test center. However, if you have multiple products or need to optimize the raw material for a specific product, we would suggest renting or purchasing a pilot unit. The typical rental period is one to three months, but many clients ultimately decide to purchase the rental unit at a fair price before the rental period expires.
Test your product before you invest: Book a trial at the GEA test center, or rent pilot equipment for your own site.
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