Ultrasonic-Assisted Freeze-Drying

Ultrasonic-Assisted Freeze-Drying (German Version)

Shorter processing times, higher throughput, and lower energy consumption

Challange:

Freeze-drying (lyophilization) is an established method for gently drying high-quality products. In this process, water is removed from a frozen product through sublimation. The process is used in particular for food, pharmaceutical products, and biotechnology applications.

Despite its advantages, freeze-drying is associated with high investment costs, significant energy requirements, and long process times. These factors limit plant throughput and increase production costs.

The Innovative Solution

The targeted use of ultrasound during the freeze-drying process can significantly accelerate sublimation.

Ice crystals form in the product during freeze-drying. Ultrasonic technology breaks down these crystals, thereby increasing the effective surface area of the ice. This leads to significantly faster sublimation and thus a considerable reduction in drying time.

A particular advantage of this technology is that it can be integrated not only into new systems but also used as a retrofit solution in existing freeze-drying systems.

Proven Results

Tests conducted in a freeze-dryer have shown that ultrasonic-assisted freeze-drying:

  • can reduce drying time by 40–60%,

  • nearly doubles system throughput,

  • and significantly reduces energy consumption at the same time.

The technology thus enables a significant improvement in the economic efficiency of existing and new freeze-drying systems.

Advantages at a glance:

  • Up to 60% shorter drying times

  • Higher system throughput

  • Reduced energy consumption

  • Lower production costs

  • Retrofittable in existing systems

  • For thermal oil or electrically heated systems

Typical Applications:

  • Instant coffee

  • Freeze-dried fruits (e.g., strawberries, raspberries, bananas)

  • Ready-to-eat meals and outdoor food

  • Pet food and snacks

  • Vaccines and pharmaceutical products

  • Biotechnology products

Conventional drying

In conventional drying, the ice crystals are very compact.

As a result, a great deal of energy is required to sublimate the moisture from the product.

Using ultrasonic technology

This innovative ultrasonic technology breaks the ice crystal into many small ice crystals, creating a larger surface area that can sublimate much more quickly.

Innovation with Direct Added Value

Ultrasonic-assisted freeze-drying combines the highest product quality with significantly improved process efficiency. Through shorter batch times, lower energy consumption, and higher production capacities, the technology offers considerable potential for cost reduction and increased sustainability in industrial drying.

  • Innovation with unique selling points, protected by patent

  • High customer benefit

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