Bulk Freeze Drying Chamber with Moveable Transfer Belts
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Solution Overview
Problem
Conventional freeze drying systems for bulk products face challenges such as inefficient heat transfer, manual handling risks, and agglomeration issues, leading to longer cycle times and irregular particle sizes, particularly in aseptic processing where sterile conditions are critical.
Innovation Solution
A bulk freeze drying system with moveable product transfer belts driven by rotating drums, a freezing vessel that generates uniform frozen particles, and a vacuum-based drying chamber with heating elements to promote sublimation, allowing for efficient and aseptic processing without the need for trays, thereby improving heat transfer and product handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tray freeze drying systems are used for bulk products, then aseptic processing can be maintained, but heat transfer efficiency is poor and cycle times are long
Solution Approach 1:
The bulk product is divided into individual frozen particles that are conveyed separately on belts rather than processed as a single mass in trays. This segmentation improves heat transfer surface area and eliminates heat transfer resistance between product and tray surfaces while maintaining aseptic conditions through continuous enclosed processing.
Solution Approach 2:
The system uses moving belts to continuously transport frozen particles through the drying chamber rather than static trays. This dynamic approach improves heat transfer efficiency by ensuring constant contact between product and heating surfaces while maintaining sterile sealed environments during continuous operation.
2Ease of operation
If manual handling of trays is used, then product can be processed, but liquid spill risks and handling losses occur
Solution Approach 1:
Manual tray handling is replaced with an automated mechanical belt conveyance system that continuously transports frozen particles through sealed chambers. This eliminates manual intervention, preventing liquid spills and handling losses while maintaining sterile conditions through enclosed automated processing.
3Productivity
If bulk product is processed in large masses, then processing capacity is high, but agglomeration occurs and particle size uniformity is poor
Solution Approach 1:
The bulk product is segmented into individual frozen particles before processing. These particles are conveyed separately on belts through the drying chamber, preventing agglomeration that occurs when bulk masses are processed together. This maintains high processing capacity while ensuring uniform particle size throughout the batch.
4Reliability
If tray-based freeze drying is used, then aseptic processing is possible, but product handling loss occurs during removal
Solution Approach 1:
Manual tray removal and product handling is replaced with automated belt conveyance that continuously transports dried particles to collection points. This eliminates manual handling steps where product loss occurs, while maintaining sterile conditions through enclosed automated processing throughout the entire pathway.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient, aseptic bulk freeze drying with improved heat transfer and reduced cycle times, producing uniform freeze-dried powder without the need for milling, while maintaining sterile conditions and ensuring product integrity.
Implementation Method 1
a vacuum port through which the drying chamber is evacuated to a first vacuum pressure
Implementation Method 2
heating elements to promote sublimation
Implementation Method 3
the ice is sublimed and the vapor flows to a condenser
Implementation Method 4
the water vapor is condensed on the condenser as ice
Implementation Method 5
A coolant is passed through the coils 122 to remove heat, causing the water vapor to condense as ice on the coils
Data Source
AI summary
A freeze drying vessel having a drying chamber and moveable transfer belts each moved by a driven drum. Each transfer belt includes a transfer surface that transports frozen particles. Each transfer surface is arranged vertically in the chamber and moves in an opposite direction than a lower transfer surface. A removal device is located adjacent each driven drum that removes frozen particles from an end of each transfer surface, respectively, to enable removed frozen particles to flow downward to a lower transfer surface. A heating element is located adjacent each transfer belt to sublimate the frozen particles to form freeze dried product.