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.

Get a quote

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.

Download more information about LYOVAC ® ECO Mode

Download here

Downloads

Produtos relacionados

LYOVAC® Pharma Freeze Dryer

GEA’s LYOVAC® industrial-scale freeze dryers are built to customer specifications and are available with production areas of 1–60 m² and condenser capacities of more than 1000 kg.

LYOVAC® Freeze dryers for small scale production modules

LYOVAC® Small-Scale Freeze Dryers

Extending its range of LYOVAC™ Freeze Dryers, GEA now offers both integrated and standalone equipment for the production of small-scale batches and formulation or process development.

Insights da GEA

Mais que um simples cafezinho: a evolução técnica da extração do café

A demanda por café está aumentando rapidamente. Descubra como a tecnologia de extração contínua da GEA aumenta o rendimento, preserva o sabor e economiza recursos.

As bombas de calor aceleram a descarbonização do aquecimento urbano

O impacto do aquecimento global é cada vez mais evidente em todo o mundo. As cidades de todos os lugares enfrentam o mesmo desafio: fornecer às suas comunidades calor confiável, acessível e de origem sustentável. A GEA conversou com um especialista na área, Kenneth Hoffmann, Diretor da divisão de Bombas de Calor da GEA Heating & Refrigeration Technologies, sobre como combater o aquecimento global mais rapidamente.

Vivendo o futuro digital da pecuária leiteira com a GEA

Algo chamou a atenção do fazendeiro Tom. Em vez de outra demonstração de produto, a GEA apresentou inovações via RA (Realidade Aumentada). Este é apenas o início da fazenda digital interativa da GEA.

Ver mais

Receba notícias da GEA

Mantenha-se atualizado com as inovações e histórias da GEA, se registrando para receber notícias sobre a GEA.

Registrar-se

Entre em contato

Estamos aqui para ajudar! Com apenas poucos detalhes poderemos responder à sua pergunta.

Entre em contato

A GEA é um dos maiores fornecedores de sistemas do mundo para os setores de alimentos, bebidas e farmacêutico. Nosso portfólio inclui máquinas e plantas, bem como tecnologia de processo avançada, componentes e serviços abrangentes. Usados em diversos setores, eles aprimoram a sustentabilidade e a eficiência dos processos de produção em todo o mundo.

A GEA está listada nos índices DAX alemão e no STOXX® Europe 600 e também está incluída entre as empresas que incluem os índices de Sustentabilidade Global DAX 50 ESG e MSCI.

Impressão & termos de uso

Aviso sobre proteção de dados

Configurações de cookies