This type of freeze dryer is designed for high efficiency food material freeze drying application. It requires a large production capacity, lower equipment cost and lower cost on energy consumption. KEMOLO focuses on manufacturing this type of freeze dryer for several years and with rich installation experience in home and abroad.
Two type of freeze dryers for your applications:
1, Contacting type of freeze dryer: better for liquid material, mainly for small or medium production. The plates and trays are constructed by stainless steel. Raw material freezing in a freeze dryer chamber. Both refrigeration and heating are on the plates, and material is loaded and unloaded tray by tray.
2, Radiant type of freeze dryer: better for solid material, mainly for medium or large scale production. The plates and trays are constructed by aluminum, with IQF. The raw material freezing is in IQF and heating on the plates, and the material is loaded by trolley on the track system.
Remarkable advantage of freeze dried food:
1, Retain biological activity
To retain biological activity as much as possible, the material must be in low temperature environment, but on the contrary, drying needs heat involved. Heating will destroy biological activity and nutrition. Our solution is to get the liquid water in the material completely frozen to solid status. The water in the material is solid ice status during the whole heating processing till the material is completely dried. So, the biological activity is retained greatly.
2, No damage to the nutrition
Heating is no doubt the main reason of nutrition damage. By using our freeze dryer, heating processing occurs after material gets completely frozen to ice status. Thus, it typically retains 97% of the nutritional value.
3, Taste, color and appearance
Lyophilized by our freeze dryer, the material still tastes fresh, delicious as a snack, but a different try. The freeze dried material remains the same color, flavor and appearance as it was firstly harvested. And the volume of freeze dried material has no change, that is to say the appearance has no shrink or toughen. It is the real high quality preserved food.
4, Longer shelf-life
Freeze dried food material has a longer preservation time than frozen food, canned food and oven drying food. Having freeze dried food storage, you do not need to rack your brains what to eat and far away from pigmentum, additive, GMO and anti-season food material. Freeze-drying help us design a healthy lifestyle.
Application of freeze dryer:
Vacuum freeze-drying technology is applied to process food material to make freeze dried food. The freeze dryer is used in all conceivable kinds of agricultural products with top drying quality.
Fruits: durian, strawberry, mango, apricot, kiwifruit, pineapple, lemon, raspberry, carambola, avocado, banana etc.
Vegetables: dill, okra, parsley, mushroom, bean, scallion, asparagus, onion, celery, carrot, tomato, pepper etc.
Other food: beef, coffee, colostrums, cordyceps sinensis, flower, tea, honey, sea food and all kinds of pets food.
In a sealed vacuum surrounding, by heating the complete frozen food material, the moisture in the frozen material will be evaporated to a continuous frozen vapor condenser. After 20-30 hours, the food material is dried, the water is moved to vapor condenser of the freeze dryer.
Construction and main components of freeze dryer:
Each single freeze dryer is composed by a vessel/chamber with shelf plates, trays and vapor condensers inside. The vessel can be cylinder shaped or square shaped.
All-in-one: for small freeze dryer, all components can be mounted on one frame. It is easy to install and ship.
Assemble: for big freeze dryer, vessel is one individual module, refrigerator is a module, vacuum pump is a module, heating system is a module, and control system is another module. We will get all modules collected on customer's site.
1, Vessel, shelf plates, trays and vapor condenser:
Shelf plates and trays can be stainless steel or aluminum, vapor condenser is made of stainless steel. The standard configuration of stainless steel is SUS304, we have SUS316 for option. The standard configuration of shelf plate is welded pieces; we have whole pieces for option.
2, Refrigeration compressor
Brand: Refcomp, Bitzer, Frascold, Hanbell, Fusheng, and Chinese local brands for your option.
The refrigeration system freezes the shelf plates during in-place freezing, evacuation and the early stages of drying. It also freezes the vapour condenser during the drying cycle. Screw type of compressor is adopted on the large scaled freeze dryer and piston for small ones, and the refrigerant used is R404A, R507 etc environment friendly Freon.
3, Vacuum pump
Brand: Edwards, Leybold, Ulvac, and Chinese local brands for your option.
The vacuum system is composed of drying chamber, condenser, vacuum pipes, valves, back pump and holding pump. It requires no leaks; Vacuum system is an essential for the rapid sublimation. Backing pumps and holding pumps are required for large scaled freeze dryer to give efficient capacity for evacuation.
4, Heating system
The heat-plates are cooled or heated with a heat transfer fluid. This fluid can be chilled or heated to provide in-place freezing or heating of the product during the drying cycle. An electric boiler directly heats the fluid, and chilling is through an intermediate heat exchanger. A centrifugal pump provides the forced circulation of the heat transfer fluid. Optional fluid: ethanol, glycol, silicon oil, deicing fluid, alcohol, water etc.
5, Defrost system
Water is used for defrosting the vapour condenser. As an optional extra, heat can be reclaimed from the refrigeration compressor to enable 60C hot water defrost, greatly reducing defrosting times over conventional cold water.
6, Control system
CE, UL approved Siemens or Advantech PLC is adopted for control system. All electrical components are compatible with local supplies including voltage, frequency, wire, motor circuit breakers and overload protection. A variety of sensors support the data acquisition and control of freeze dryer: Pressure transducers are fitted, which monitor and control the refrigeration system. Vacuum pressure is monitored at the product chamber. Temperature sensors measure and control the heating fluid.
Installation and training:
We have engineers with many years installation experience available for our freeze dryer installation guidance and service; and train customer's workers operate the machine.
Packing and delivery:
Small freeze dryer normally packed by wooden box and shipped by standard container. If export to European countries or north America countries, the wooden box will be fumigated. As the chamber of large scale freeze dryer, the chamber is shipped by Flat Rack container, the rest normally packed by wooden box and shipped by standard container.
1, Large scaled production capacity: from 50-5000kg per batch (24 hours).
2, Equipment with certificates of ISO, CE, ASME etc is an optional choice. You can also choose the best local brand equipment as an option to save your cost.
3, 220V, 380V, 50Hz is the standard configuration; 110-120, 60Hz, 400-480V, 60Hz is optional.
4, Auto tracking loading system as a standard configuration radiant type of freeze dryer.
5, Manual loading for contacting freeze dryer as an option.
6, IQF (Individual Quick Freezing) for radiant type of freeze dryer.
7, Steam or electricity is optional for material heating to save your energy cost.
8, Recyclable hot-water defrost system to improve the working efficiency and save energy cost.
9, All-in-one freeze dryer to shorten installation time to 2-3 days for small-scaled freeze dryer; and meanwhile provide modularized units to shorten installation time for large-scaled freeze dryer. The freeze dryer will be designed according to customer's detail requirement.
10, Engineers available for the over sea's installation of freeze dryer.