Vacuum Pump for Freeze Drying (Lyophilization)
What Is Freeze Drying(Lyophilization) and How Does It Work?
Freeze drying, also known as lyophilization, is a low-temperature dehydration process used to preserve perishable materials or make them more convenient for transport and storage. It’s widely used in the pharmaceutical, biotech, and food industries to maintain product integrity, shelf life, and effectiveness.
How It Works: The Lyophilization Process
Freezing
The product is first frozen to convert water into solid ice. This step ensures the material retains its shape and structure.Primary Drying (Sublimation)
Under a vacuum, the ice turns directly into vapor without passing through the liquid phase. This is called sublimation and requires careful control of temperature and pressure.Secondary Drying (Desorption)
Remaining moisture molecules bound to the material are removed by gradually increasing the temperature under continued vacuum. This final step ensures the product is thoroughly dried.
The result? A lightweight, shelf-stable product that can be easily rehydrated without compromising texture, nutrients, or bioactivity.
How Vacculex Vacuum Pumps Provide Solutions
VSP Series Screw Vacuum Pump
Engineered for precision and purity, the VSP Series delivers oil-free, contamination-free vacuum performance critical for thin film evaporation processes. Its synchronized counter-rotating helical rotors ensure efficient gas compression and expulsion—eliminating the risk of oil backstreaming that can compromise product quality in sensitive applications.
MB Series Mechanical Vacuum Booster
Engineered to excel in the most demanding thin film evaporation processes, the MB Series combines rugged reliability with precision engineering. Its five-point bearing system and dual oil tanks deliver unmatched stability, while the nitrogen gas barrier actively prevents oil contamination—critical for maintaining purity in high-temperature, high-vacuum applications.
Why Choose Vacculex Vacuum Pump for Lyophilization?
Vacculex vacuum pumps are engineered for precision and performance in freeze-drying applications. With powerful vacuum stability, oil-free technology, and high resistance to moisture, Vacculex ensures faster sublimation, cleaner processing, and longer equipment life. Trusted by pharmaceutical, biotech, and food industries worldwide — Vacculex delivers reliability where it matters most.
Ultra-Low Pressure Performance
Vacculex pumps deliver industry-leading vacuum levels down to 0.003 mbar, ensuring optimal sublimation conditions. They provide:
✔ Gradual pitch screw rotors for stable vacuum maintenance
✔ 25% faster cycle times compared to conventional pumps
✔ Consistent performance even with volatile solvents
Oil-Free, Contamination-Free Operation
Vacculex vacuum pumps ensure a clean, oil-free environment, making them ideal for high-purity applications. They provide:
✔ No oil seals or lubricants, preventing contamination
✔ Ideal for sensitive materials in pharmaceutical, chemical, and food industries
✔ Consistent, high-quality output with minimal risk of contamination
Advanced Thermal Management
Our pumps maintain optimal operating temperatures even during extended freeze drying cycles. They provide:
✔ Precision temperature control to prevent rotor deformation
✔ Protection against heat-related coating damage
✔ Stable performance in continuous operation environments
Corrosion-Resistant Construction
Vacculex pumps withstand aggressive process conditions. They provide:
✔ PEEK-coated rotors for superior chemical resistance
✔ Nitrogen gas barriers to prevent internal corrosion
✔ Long service life in harsh operating environments
The Process of Freeze Drying (Lyophilization)
Sublimation Stage (Primary Drying)
During freeze drying, moisture is removed by sublimating ice directly into vapor under low temperature and low pressure. Vacuum pumps reduce the chamber pressure to around 0.1 to 1 mbar, creating the ideal environment for sublimation.
🔧 Vacuum pump functions at this stage:
- Creates low-pressure conditions to enable sublimation
- Maintains product stability by avoiding the liquid phase
- Increases drying efficiency and reduces process time
Vapor Transfer to the Condenser
Water vapor generated from sublimation needs to be quickly removed from the product area and directed toward the condenser. Vacuum pumps create a constant pressure gradient to support this vapor migration.
🔧 Vacuum pump functions at this stage:
- Maintains continuous vapor flow from the product to the condenser
- Helps prevent vapor condensation near the product
- Supports efficient moisture capture in the condenser unit
System Evacuation (Start-Up Phase)
Before freeze drying begins, the system must be fully evacuated to create the required vacuum environment. Vacuum pumps handle the initial air removal from the drying chamber and connected pipelines.
🔧 Vacuum pump functions at this stage:
- Rapidly reduces chamber pressure before drying starts
- Ensures a clean and stable vacuum environment
- Prepares the system for consistent and effective operation
Request a Quote for Vacculex Vacuum Pump Today!
Discover the perfect vacuum solution for your lyophilization needs. Contact us now for pricing and expert assistance!
FAQ
Freeze drying(lyophilization) typically operates in two pressure ranges:
Primary Drying (Sublimation): 0.01–0.03 mbar
Secondary Drying (Desorption): 0.1–0.3 mbar
How Vacculex Delivers Precision:
| Feature | VSP Series Screw Pump | MB Series Booster |
|---|---|---|
| Ultimate Pressure | 0.003 mbar | Supports down to 0.001 mbar |
| Pressure Stability | ±0.5% fluctuation | ±1% fluctuation |
| Critical Technology | Gradual pitch rotors | High-speed compression |
| Ideal Phase | Primary drying | Secondary drying |
Vacculex pumps combine oil-free screw rotors (for low-pressure sublimation) with boosters (for rapid vapor removal), ensuring seamless transition between phases without contamination risks.
Key Risks of Oil-Lubricated Pumps:
Hydrocarbon Contamination: Backstreaming oil vapors can compromise sterile products (e.g., vaccines, injectables).
FDA Compliance: 21 CFR Part 11 requires zero lubricant contact with process gases.
Maintenance Costs: Oil changes and filter replacements increase downtime.
Vacculex Solutions:
✔ 100% Dry Pumps: No oil in gas path (PEEK-coated rotors)
✔ Nitrogen Barriers: Prevent vapor ingress into bearings
✔ Validatable Design: Documentation packages for GMP audits
Feed Distribution – The liquid enters the evaporator and is evenly distributed into a thin film using a rotating or falling-film mechanism.
Heat Transfer & Evaporation – The thin film is heated, causing rapid evaporation of volatile components at reduced boiling points.
Separation Under Vacuum – A vacuum pump maintains low pressure, allowing sensitive compounds to evaporate at lower temperatures, preventing degradation.
Condensation & Collection – The evaporated vapors are condensed and collected separately, while the remaining concentrated product exits the system.
Comparative Analysis (Based on 100L Lyophilizer):
| Parameter | Conventional Pump | Vacculex FD-300 | Savings |
|---|---|---|---|
| Power Draw | 18.5 kW | 12.1 kW | 35% |
| Annual Energy Cost* | $9,200 | $5,980 | $3,220 |
| CO₂ Emissions | 48.3 tons | 31.4 tons | 16.9 tons |
| *Calculated at $0.12/kWh, 24/7 operation |
Efficiency Drivers:
IE4 Motors: 96% efficiency vs. 89% (IE2)
Adaptive Speed Control: Reduces power during low-load phases
Maintenance Comparison:
| Task | Standard Pump | Vacculex Pump | Interval Extension |
|---|---|---|---|
| Rotor Inspection | 3,000 hours | 8,000 hours | 2.7X |
| Seal Replacement | Annual | 3–5 years | 4X |
| Oil Changes | Quarterly | None | N/A |
Proactive Features:
Smart Monitoring: Vibration/temperature sensors alert before failures
Modular Design: Replace rotors without full disassembly
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