"Add better" environmental label for LYOVAC®ECO mode from GEA

The freeze-drying process is usually associated with high energy consumption. With the LYOVAC®ECO mode, GEA optimizes the energy consumption of pharmaceutical freeze-drying systems. Validations and comparisons with previous solutions and models and international standards have shown a possible reduction in power consumption of around 20 percent. The LYOVAC®ECO mode has now been awarded the "Add Better" environmental label on the basis of demonstrable resource conservation and a stringent evaluation process developed by GEA in collaboration with TÜV Rheinland. For customers, the traceable test process means maximum transparency.

Freeze-drying systems with liquid condenser can be retrofitted with the LYOVAC®ECO mode

The LYOVAC®ECO mode combines dynamic condenser temperature and plate valve control (chamber/condenser) to improve the freeze drying process. This optimization does not affect the freeze dryer's ability to process existing formulations, making it an efficient upgrade. ECO mode can be retrofitted to all appliances with a liquid condenser and offers the option of running existing processes in classic mode. This is a selectable recipe parameter that changes the future of freeze drying towards more environmental friendliness.

The path to the top rating and validation of the test process by TÜV Rheinland

After extensive internal testing to compare the coefficient of performance (COP) and energy consumption of the ECO mode with the theoretical value of a two-stage reciprocating compressor, GEA carried out further experiments on a production-scale freeze dryer. Using a LYOVAC®)FCM 500-D machine with a shelf area of 22.3 m2   and a total run time of 46.55 hours, energy savings of 401.32 kWh were achieved, which corresponds to a reduction in electricity consumption of 21.1 percent. 

"No colder than necessary"

Thomas Beutler, Senior Director Lyophilization Technology Management at GEA Lyophil, explains: "Our new algorithm changes the setpoint for both the temperature of the liquid condenser and the position of the plate valve during the drying process. This means that there is no longer a fixed temperature for the condenser. It is optimally adapted to the ongoing process and is no colder than necessary."

Validated by TÜV Rheinland

As an independent testing body, TÜV came to the conclusion that the TYPE II "ADD BETTER" eco-label developed by GEA Lyophil GmbH is appropriate, transparent and suitable for the "LYOVAC ECO Mode" application in accordance with the DIN EN ISO 14021:2021-10 standard. It also found that the data provided is "coherent and understandable" and can be used in communication, marketing or documentation to demonstrate to customers and stakeholders that the environmental and/or technical claims have been independently verified.
"Independent verification provides external confirmation that our energy saving claims are consistent and scientifically sound," says Thomas Beutler. "The use of the term "Validated by TÜV Rheinland" gives our customers the certainty that the sustainability benefits of ECO mode are not just internal estimates, but have been independently verified. It reflects the certainty that this retrofittable technology delivers clear, technically thorough and measurable improvements in efficiency and environmental performance with no detrimental impact on the end product."

More GEA freeze drying solutions for energy and media savings

Some GEA solutions are already available to help users and operators of industrial and commercial freeze dryers achieve their sustainability goals, such as the LYOAIR®cooling system, which uses natural refrigerants, and novel concepts such as microwave-assisted and atmospheric spray drying.

Background information

The "Add Better" environmental label - developed with TÜV Rheinland

The Add Better label identifies solutions from GEA that are significantly more efficient and environmentally friendly than their respective predecessor product. From machines and processes to digital solutions and entire plants. The process underlying GEA's Add Better label fulfills the ISO requirements for environmental supplier declarations, including specific assessment and testing methods. The first step in the process is the selection of the solutions to be evaluated by an interdisciplinary team of experts from GEA. This includes a detailed description of the technology and its application. GEA then defines the technical, geographical and temporal scope of the solution and its analysis. On this basis, relevant data on the current technology and the previous version is collected and reviewed. The process for data collection, calculations and detailed documentation of the results was developed in collaboration with TÜV Rheinland. In a final step, GEA's Global Executive Committee reviews the results to ensure that the efficiency improvement achieved really justifies the Add Better label. The underlying assessment process - from data collection to calculations and documentation - complies with ISO standard 14021:2016. The aim of the process is to maximize transparency for GEA customer.