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Hosokawa Micron B.V. was recently granted a new patent for the Active Freeze Dryer. This unique invention offers several advantages, compared with the traditional tray freeze drying approach for high-end pharmaceuticals.
Most pharmaceutical manufacturers are used to the traditional tray drying method. However, there are several challenges associated with this traditional approach which we set out to solve with the AFD – and this patent recognizes that we have succeeded in solving them. The key innovations are the improved process control and the options for choosing where the dried product is collected, such as at the bottom of the dryer or in the filter.
The fact that the AFD produces powder rather than a cake is not only a benefit in terms of the potential of eliminating the post-processing phase of grinding or crushing. The end product resulting from the AFD is of superior quality; it is a fine, free-flowing powder. Because freezing in the AFD is vacuum-induced, the freezing phase is better controlled and results in a granular, snow-like ice structure.
The AFD is a fully sterile set-up: there is minimal operator interference, from when the suspension or solution is charged to the vessel right through to the aseptic discharge of the powdery product to a canister. The AFD is a fully automated system including CIP and SIP cycles, offering excellent cleanability.
