Freeze Drying Systems

From high-tech pilot plants to high-efficiency production plants

Freeze drying systems / lyophilization - OPTIMA pharma
Thanks to state-of-the-art freeze-drying processes, pharmaceutical products are becoming much more durable and suitable for long-term storage. Freeze drying systems from OPTIMA Pharma offer a wide range of modern equipment primarily used to freeze dry medications. We will accompany you from the beginning to the process design and implementation of the ideal lyophilization system for your needs and applications. This includes initial and laboratory testing as well as the detailed development of all necessary freezing processes.

Sensitive pharmaceutical products often need to be freeze-dried to help preserve shelf life. OPTIMA 
provides solutions for all freeze-drying requirements with a broad range of machines, from high-tech to high-efficiency production machines for vials, syringes, injectables, and ampoules both as single units and in bulk.

OPTIMA has a modern, state-of-the-art, manufacturing site with all of the required equipment for different processes available. We can install, test and operate freeze-drying equipment under real conditions, saving time and money for both the qualification (IQ/OQ) and final site installation (SAT).

Lyophilization Solutions

Lyophilization can extend the life of highly sensitive pharmaceutical and biotechnical produced drugs significantly. Therefore, the production of many pharmaceutical drugs and heat-sensitive medications are inconceivable without it. OPTIMA’s portfolio includes freeze dryers for both the mass production and small batches of pharmaceutical products. As a leading freeze dryer manufacturer, OPTIMA designed freeze driers specifically for the pharmaceutical industry. OPTIMA Pharma’s state-of-the-art building provides the latest technology to meet customer needs. The following media are available for all necessary processes: pure steam, CIP medium, and liquid nitrogen. The assembly, commissioning and FAT are completed in a two-story building, facilitating tests and machine inspections under real-life conditions. Therefore, saving valuable time during installation, qualification (IQ, OQ) and the final performance test (SAT). From start to finish, OPTIMA is your partner to design the perfect lyophilization system.
Process based
3D engineering
Phase-oriented
Project management
IQ/OQ/PQ
Quality assurance
Integration in
Turnkey lines

Freeze drying systems from OPTIMA pharma

Innovative, forward-looking technology to meet your unique requirements in lyophilization

Freeze drying system - loading system

Your needs are in focus

Process requirements, product characteristics, spatial limitations and desired level of automation are considered during the design. The manufacturing, testing, installation, and commissioning can be performed at our pharmaceutical facility in Mornshausen.
Freeze drying system - Modern building infrastructure - OPTIMA pharma

Modern building infrastructure

Single and dual floor units can be built and installed to mimic the architecture of the final site, allowing the simulation of potential conflicts before equipment installation. The installation, de-installation, and transportation of the machine are fully prepared in the factory and the machine units are shipped in sealed trucks. This method ensures optimal delivery and quick installation.

Further Information

Get more information on freeze drying systems, solutions, and services from OPTIMA pharma.

Lyophilization Process Technology

Focus on process safety and efficiency. Interview partner: Stephan Reuter, Managing Director Optima Pharma

What is lyophilization?

Freeze-drying, also known as lyophilization or sublimation drying, is a method of careful drying of high-quality products. In freeze-drying, the ice crystals sublimate without passing into a liquid state. The end product of freeze-drying is known as lyophilization which is completed in a batch process.
 


Lyophilization Process

As a rule, freeze-drying equipment consists of two containers. The chamber and condenser are connected to each other with a valve and the product to be lyophilized rests on temperature controlled surfaces. During the lyophilization cycle, the product is freeze-dried under atmospheric pressure. 

In the primary freezing phase, the water contained in the material is sublimated. To achieve this, a vacuum is created and energy is absorbed through sublimation. In order to keep the product temperature constant, the surfaces are subjected to the same amount of heat that is being used by the water as sublimation energy.

Next in the freeze-drying cycle is secondary drying, whereby, through further heating, more strongly bonded water is removed from the product to make it dry. The cooling of the set-up surfaces is completed using heat exchangers that are connected to the primary refrigeration system. A condenser creates a low-temperature atmosphere, typically between -75 °C and −90 °C.

 

Economic Freeze-Drying of Small Batches

In the primary drying phase the water contained in the material is sublimated. This is based on the principle that also when frozen, water has sufficiently high vapor pressure to pass from frozen directly to gaseous state. For this a vacuum is created.
Energy is taken up in sublimation. This energy is drawn from the surrounding temperature and so in the course of the process the temperature of the set-up surface would drop. In order to keep the temperature constant the set-up surfaces are subjected to the same amount of heat as is taken up by the water as sublimation energy. In the course of the drying process the atmosphere in the chambers consists almost exclusively of water vapor that precipitates as ice on the cold coiled pipes of the condenser. 

 

Suitable for Functional Floor Separation

Because of its unique two-story design, the D Freeze Dryer is very easy to integrate into an existing machine concept. The machine’s small footprint permits installation even with limited space. The freeze dryer design offers a functional separation of the clean room and the machine section. Your employees also benefit from a service door that can be integrated on the side.

 

Reduce Your Production Cost

Heated shelves control the temperature profile during the freeze-drying process. One hundred percent of the usable space on our shelves is evenly cooled by convection. The shelves are manufactured by OPTIMA with the latest calculation tools and innovative technology. Our patented design increases output and reliability and reduces production costs compared to other products. Each shelf has a serial number that permits the traceability of all parts and manufacturing phases. The inspection of the raw material and tests during the manufacturing process guarantees absolute reliability and longevity.