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Freeze Dryer

Lyophilizer Manufacturers in India

Freeze Dryer

If you are looking for economical and cutting-edge solutions in freeze drying, you can stop your search at GEM. We are a pioneering freeze dryer manufacturer in India, delivering high-end lyophilizer technology machines. Our dryers are best suited for food and chemical applications.

Principle of Freeze Drying (Lyophilization)

The principle of freeze drying is based on the sublimation of ice — the direct conversion of water from the solid (ice) phase to the vapour phase without passing through the liquid state.

This process removes moisture from heat-sensitive materials such as biological products, pharmaceuticals, and food, while preserving their structure, nutrients, and volatile components.

Key Steps in the Freeze Drying Process

  • Freezing:

    • The product is first cooled below its eutectic or glass transition temperature (typically –30°C to –50°C).
    • Water in the product solidifies into ice, and solutes concentrate in the unfrozen regions.
  • Primary Drying (Sublimation):

    • Under high vacuum (typically 0.05–1.0 mbar), gentle heat is applied to supply the latent heat of sublimation.
    • Ice sublimes directly into vapour and is removed from the product.
    • Vapour is captured on a condenser (cold trap) maintained at very low temperature (–40°C to –80°C).
    • About 90–95% of the water is removed in this stage.
  • Secondary Drying (Desorption):

    • The temperature is gradually increased (20–40°C) under vacuum to remove residual bound moisture.
    • Final moisture content is typically <1–2%.
    • The product is then sealed under vacuum or inert gas to prevent reabsorption of moisture.
  • Construction of a Freeze Dryer

A freeze dryer (lyophilizer) consists of several key components integrated to perform the three stages above under controlled conditions.

Main Components and Their Functions

ComponentFunction
Drying Chamber (Product Chamber)
  • Holds the trays or shelves containing the product.
  • Constructed from stainless steel (SS304/SS316) with polished internal surfaces for hygiene.
  • Fitted with temperature-controlled shelves (heating/cooling) and a vacuum-tight door with gasket.
Shelves / Trays
  • Hollow shelves with channels for circulating heat transfer fluid (glycol, silicone oil, or Freon).
  • Used to freeze and later supply controlled heat during drying.
  • Shelf spacing typically 50–100 mm.
Refrigeration System
  • Provides the cooling required for freezing the product and for the condenser.
  • Uses a two-stage refrigeration system with evaporator coils reaching –40°C to –80°C.
Vacuum System
  • Maintains the low pressure needed for sublimation.
  • Comprises a rotary vane vacuum pump or dry scroll pump, sometimes with a roots blower for deeper vacuum.
  • Typical operating pressure: 0.05–1 mbar.
Condenser (Cold Trap)
  • Positioned between the drying chamber and vacuum pump.
  • Maintained at a temperature lower than the product (–40°C to –80°C).
  • Water vapour from sublimation condenses as ice on its coils, protecting the vacuum pump.
Heating System
  • Provides controlled heat input to the shelves during sublimation and desorption.
  • Uses circulating thermal fluid (oil or glycol) with precise temperature control (±1°C).
Instrumentation and Controls
  • Monitors and controls temperature, pressure, vacuum level, and drying cycle.
  • Modern systems use PLC–HMI automation to run programmed freeze-drying cycles.
Product Containers
  • Depending on design, the product is held in trays, vials, bottles, or bulk pans.
  • Laboratory dryers often use flasks attached to a manifold, while industrial units use shelf-based trays.

Advantages

of nutrients, enzymes, probiotics, flavors, and heat-labile actives

(high porosity, rapid wetting, low density, minimal shrinkage)

with low residual moisture and minimal oxidation (inert backfill)

via recipe control, data logging, and PAT tools

with CIP/SIP, sterile boundary, and stoppering for vials

no melting, scorching, or case hardening

liquids, purees, gels, crystals, sensitive biomolecules

Features

01

Shelf technology

wide temp range, fast ramp rates, uniformity mapping; bulk trays or vial handling

02

Condenser system

high hold-up and pull-down rate with hot-gas defrost for rapid turnaround

03

Vacuum & measurement

dry pumps, capacitance manometer & Pirani, pressure-rise/MTM endpoint checks

04

Controls & compliance

PLC-HMI/SCADA, recipes, batch reports, alarms,

05

Hygiene: CIP spray balls,

SIP with clean steam, aseptic drain paths, FDA-compliant elastomers

06

Safety & reliability

redundant temp/pressure sensors, door interlocks, leak detection, vacuum break with sterile gas

07

Integration options

automatic loading, vial stoppering, lyo caps, WFI/clean-steam utilities, remote diagnostics

Applications

Food_Beverage_Processing

Industries

gemicn

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insights of our Freeze Dryer.

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Our Clients

Our Testimonial

Unicoco, Indonesia was excited about the Coconut project, but through GEM we made this dream come true. GEM machines: dryers / screw conveyors / bleachers / graders, etc. they are absolutely good and require little maintenance. Also, we get 24×7 support from them in case we get stuck at any time.

GO FOR IT!!!

Anoop Khandelwal

Owner and CEO

PT Unicoconut Industries Indonesia, Indonesia

Franklin Baker Company of the Philippines, in its continued effort to be the gold standard in processed coconut products, continues to partner with the best OEM suppliers for our manufacturing line requirements. One of them is GEM Forgings, which has been our trusted supplier of process equipment for our DC (desiccated coconut) dryers. We both value quality and service level in our business dealings.

Cesar Q.Galvez

Vice President - Operations

Franklin Baker Company of the Philippines

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