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The era of synthetic refrigerants is coming to an end. Regulatory requirements are accelerating their phase-out, while demands for process safety and sustainability continue to rise. In the face of climate change, environmentally friendly technologies are a requirement.
Optima offers solutions that actively shape this transition: natural refrigerants in cascade systems, liquid nitrogen, and air-based cooling units. This ensures long-term production reliability, regulatory compliance, and a reduced carbon footprint.
OPTIMA solutions FAQWith the revised EU F-Gas Regulation 2024 and international agreements such as the Kyoto Protocol, fluorinated refrigerants are facing increasing regulatory pressure. The clear objective: a near-complete phase-out of climate-damaging F-gases, particularly hydrofluorocarbons (HFCs).
The key factor is the GWP value – the higher the global warming potential, the sooner a ban is likely.
Natural refrigerants offer negligible global warming potential and excellent thermodynamic properties. They enable compact, energy-efficient systems using standard reciprocating compressors and globally available service support. Cascade systems combine two separate circuits with different refrigerants and cool the ice condenser indirectly.
When installed in ventilated housings with gas detection systems and low refrigerant charges, only minimal explosion protection is required. Appropriate sensors and active ventilation ensure complete system safety.
As a refrigerant, air offers an environmentally friendly alternative to conventional refrigeration systems in freeze dryers. In a closed-loop system, air is cooled via the Joule-Thomson effect and used to chill silicone oil down to -80 °C and below. This technology is virtually maintenance-free, incurs low operating costs, and eliminates typical refrigerant risks such as leakage, toxicity, or flammability.
This equipment can provide the required level of refrigeration capacity without the need to connect an additional cooling source (LN2 or buffer tanks). The specific configuration is determined by the customer’s requirements, existing infrastructure, and available space.
Liquid nitrogen is used to cool both the product shelves and the condenser. In a shell-and-tube heat exchanger, LN₂ evaporates and cools the silicone oil, which is circulated by pumps to ensure even temperature distribution across the shelves. The condenser can be cooled either directly via LN₂ evaporation or indirectly via a second silicone oil circuit.
Key advantages include compact installation, fewer components, and minimal maintenance. Cooling water is not needed, and operational energy consumption is low. Although LN₂ is a natural refrigerant that offers an environmentally friendly solution, the energy required for its production and the necessary infrastructure must be taken into account.
The combination of a cascade system and liquid nitrogen unites the advantages of both technologies: the high energy efficiency and availability of the cascade with the rapid, ultra-low cooling power of LN₂. This allows load peaks to be managed, freezing times to be reduced, and maximum process reliability to be ensured. The solution is flexibly adaptable and delivers dependable cooling even under the most demanding production conditions.
Natural refrigerants offer negligible global warming potential and excellent thermodynamic properties. They enable compact, energy-efficient systems using standard reciprocating compressors and globally available service support. Cascade systems combine two separate circuits with different refrigerants and cool the ice condenser indirectly.
When installed in ventilated housings with gas detection systems and low refrigerant charges, only minimal explosion protection is required. Appropriate sensors and active ventilation ensure complete system safety.
As a refrigerant, air offers an environmentally friendly alternative to conventional refrigeration systems in freeze dryers. In a closed-loop system, air is cooled via the Joule-Thomson effect and used to chill silicone oil down to -80 °C and below. This technology is virtually maintenance-free, incurs low operating costs, and eliminates typical refrigerant risks such as leakage, toxicity, or flammability.
This equipment can provide the required level of refrigeration capacity without the need to connect an additional cooling source (LN2 or buffer tanks). The specific configuration is determined by the customer’s requirements, existing infrastructure, and available space.
Liquid nitrogen is used to cool both the product shelves and the condenser. In a shell-and-tube heat exchanger, LN₂ evaporates and cools the silicone oil, which is circulated by pumps to ensure even temperature distribution across the shelves. The condenser can be cooled either directly via LN₂ evaporation or indirectly via a second silicone oil circuit.
Key advantages include compact installation, fewer components, and minimal maintenance. Cooling water is not needed, and operational energy consumption is low. Although LN₂ is a natural refrigerant that offers an environmentally friendly solution, the energy required for its production and the necessary infrastructure must be taken into account.
The combination of a cascade system and liquid nitrogen unites the advantages of both technologies: the high energy efficiency and availability of the cascade with the rapid, ultra-low cooling power of LN₂. This allows load peaks to be managed, freezing times to be reduced, and maximum process reliability to be ensured. The solution is flexibly adaptable and delivers dependable cooling even under the most demanding production conditions.
The cooling requirements of product shelves and ice condensers depend heavily on the specific recipe and loading conditions. With alternative refrigeration systems, it is often advisable to use a separate cooling circuit—or even a second system—to optimally meet the demands of both components.
In temperatures between –80 °C and –70 °C, the cascade system using R1270/R170 offers better energy efficiency than cold air technology. Below –70 °C, however, cold air systems achieve a higher coefficient of performance (COP). Liquid nitrogen systems (LN₂) show the lowest COP values across the entire temperature range and are therefore significantly less efficient.
Digital twins enable Optima to simulate production processes in advance. Proprietary calculation tools validate the system design and determine the maximum sublimation rate for accurate component sizing.
Intelligent frequency converters significantly reduce the consumption of steam, water (WFI or PW), liquid nitrogen, and electricity. This lowers your operating costs and increases the sustainability of your production.
With a scientific approach and early-stage consulting, we take all framework conditions into account from the outset – from utilities to formulations – thereby minimizing risks, avoiding deviations, and ensuring a smooth process.
Optima’s experience in all common refrigeration technologies means our team can provide independent, unbiased consulting. This ensures you get the cooling solution that fits your processes, infrastructure, and system layout perfectly.
Through comprehensive comparisons of all available systems – including total cost of ownership – we offer you the most technologically advanced, economically efficient, and sustainable solution.
We will send you the Whitepaper on the topic of Alternative Refrigeration. You will receive an e-mail with a download link.
Are you looking for solutions that combine compliance and sustainability?
Our whitepaper provides a detailed overview of modern freeze-drying and explores how alternative cooling systems are revolutionizing the industry. It highlights Optima's innovative solutions, including cascade systems with natural refrigerants, liquid nitrogen, cold air, and hybrid cascade/liquid nitrogen systems.
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