Drying
Adopting energy-efficient drying technology, it enables continuous and automated production, ensuring excellent batch-to-batch consistency. It efficiently handles a wide variety of complex materials, including high-moisture, highly sticky, and heat-sensitive types, while providing precise control over powder moisture content and morphology.
Active Freeze Dryer AFD
The Active Freeze Dryer (AFD) is a cutting-edge freeze drying technology that produces free-flowing bulk pharmaceutical powders – including antibiotics, hyaluronic acid, injectables, peptides and PLGA – in a closed, one-pot process.
Principle of Operation
In the Active Freeze Dryer, the product is frozen while being agitated in a specially designed lyophilisation chamber. Whether the material to be dried is initially liquid, granular solid or a paste, the agitated freezing process ensures that it solidifies in the form of free-flowing, snow-like granules.
Once the product is fully frozen – a process that takes place rapidly – sublimation begins. Heat supplied via the jacket is efficiently transferred through the agitated product, enabling fast and uniform drying. As the ice sublimates, the coarse frozen granules shrink, forming a fine, loose, dry powder. After vacuum release, the chamber is opened and the dry powder discharged.
Thanks to the dynamic freeze drying process, the end product consists of porous granules with excellent flow properties and (re)dispersibility. Compared to traditional tray freeze drying, this process significantly reduces drying time and eliminates the need for manual handling.
Features
One-pot freeze drying of high-value pharmaceutical powders
Contamination-free and minimal handling
Fine, free-flowing and uniform end product
Excellent cleanability, CIP included
Aseptic processing and SIP features optional
Available in sizes from 1–1,500 L
Specifications
| Model | Max. batch volume | Indicative sublimation capacity |
|---|---|---|
| 1 | 0.5 | 0.1 |
| 5 | 2.5 | 0.3 |
| 20 | 10 | 0.8 |
| 60 | 30 | 1.7 |
| 100 | 50 | 2.2 |
| 200 | 100 | 3.4 |
| 500 | 250 | 7.2 |
| 800 | 400 | 9.9 |
| 1000 | 500 | 11.4 |
| 1500 | 750 | 13.7 |
experimental verification
Before investing in new equipment, please conduct tests on the materials to be used at the Hosokawa Testing and Process Development Center based on actual production conditions. Our experienced experts will assist you in determining the most effective mixing, granulation, or drying processes, helping you transition from laboratory testing to a comprehensive production testing phase. Whether you need to test the performance of a single machine or evaluate the entire production line, we can provide tailored testing services and process optimization solutions to ensure reliable system operation and excellent performance.
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