LYOVAC® ECO Mode: A Solution for Tomorrow.

Freeze dryers are typically associated with high levels of energy consumption. To counteract this issue, GEA Pharma & Healthcare has introduced the LYOVAC® ECO Mode.

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With a focus on saving both energy and media, GEA’s new LYOVAC® ECO Mode combines dynamic condenser temperature control and mushroom (chamber/condenser) valve regulation to optimize the lyophilization process. With this new algorithm-based solution, GEA is poised to make freeze drying greener and more efficient, offering a practical, eco-friendly solution for the pharmaceutical industry to meet its sustainability goals.

ECO Mode was developed to reduce overall energy demand based on real-time process needs, cutting energy use by ensuring the condenser is only as cold as necessary. This approach eliminates the need for a fixed condenser temperature, significantly reducing the load on refrigeration systems and minimizing nitrogen requirements to maintain the chamber pressure.

By allowing the condenser coils to run at a warmer temperature, energy savings during cooling of up to 60% can be achieved without compromising product quality. This optimization does not affect the freeze dryer’s capability to handle existing formulations, making it an efficient upgrade.

Putting Theory into Practice

A series of initial tests was done using a LYOVAC® FCM 2 to compare the coefficient of performance (COP) and process energy consumption of the ECO Mode with the theoretical value of a two-stage reciprocating compressor (R507). Using 3% mannitol as the test product and taking an average of five trial runs, the results were impressive.

In both situations (with a constant condenser temperature of ≤–70 °C for the classic mode and a dynamic condenser temperature not colder than –53 °C for the ECO Mode) and using pressure rise measurement [PRM] to determine the end of primary and secondary drying, the processing times for both the classic and ECO Mode were very similar .

LYOVAC® ECO Mode: A Solution for Tomorrow

There was no observed influence on residual moisture and it was calculated that more than 50% of the cooling capacity could be saved during primary drying (PD). During secondary drying (SD), the energy savings were lower because of the lower set pressure. Yet, because of the COP, the electrical power savings in the fluid compressor were significantly higher.

Further trials were then done with 5% sucrose. Again, taking an average of five runs, the ECO Mode process time was slightly higher; but, as per the mannitol tests, more than 45% of the cooling capacity could be saved during PD. Likewise, significant electrical energy savings could be made with no influence on residual moisture .

In Summary

This new algorithm changes the set point of both the fluid condenser temperature and the position of the mushroom valve during drying. What this means is that there’s no longer an actual fixed temperature for the condenser; it’s optimally matched to the ongoing process and no colder than necessary.”

In addition, the mushroom valve opening position can optionally be used as an extra control mechanism … as well as the nitrogen inflow rate. This allows the freeze dryer to reach the same chamber pressure, but with warmer condenser coils. As such, less nitrogen is needed to control the pressure. The system can also be augmented with a virtual sublimation sensor if required.

Retrofit-compatible with any unit with a fluid condenser, and with the option to run existing processes in classic mode, ECO Mode will be a selectable recipe parameter that will transform the future of planet-friendly freeze drying.

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