The Active Freeze Dryer (AFD) is a specialised vacuum freeze-drying system developed by Hosokawa Micron. It enables contamination-free, sterile production of free-flowing pharmaceutical powders in a single, enclosed process — with minimal manual handling and no post-processing.
Menu
LYOPHILISATION SYSTEM
for producing free-flowing, sterile bulk pharmaceuticals
Active Freeze Dryer
Lyophilisation System
The Active Freeze Dryer (AFD) is a cutting-edge freeze drying technology that produces free-flowing bulk pharmaceutical powders – including antibiotics, hyaluronic acid, injectables, peptides and PLGA – in a closed, one-pot process. Unlike conventional tray freeze dryers, the AFD requires no operator intervention or post-processing, offering unmatched efficiency, minimal handling and consistent, uniform powder output directly from the product collector. Customers often describe the quality of the resulting powder as ‘revolutionary’.
Key Benefits
- One-pot freeze drying of high-value pharmaceutical powders
- Contamination-free and minimal handling
- Fine, free-flowing and uniform end product
- Excellent cleanability, CIP included
- Aseptic processing and SIP features optional
- Available in sizes from 1–1,500 L
Principle of Operation
In the Active Freeze Dryer, the product is frozen while being agitated in a specially designed lyophilisation chamber. Whether the material to be dried is initially liquid, granular solid or a paste, the agitated freezing process ensures that it solidifies in the form of free-flowing, snow-like granules.
Once the product is fully frozen – a process that takes place rapidly – sublimation begins. Heat supplied via the jacket is efficiently transferred through the agitated product, enabling fast and uniform drying. As the ice sublimates, the coarse frozen granules shrink, forming a fine, loose, dry powder. After vacuum release, the chamber is opened and the dry powder discharged.
Thanks to the dynamic freeze drying process, the end product consists of porous granules with excellent flow properties and (re)dispersibility. Compared to traditional tray freeze drying, this process significantly reduces drying time and eliminates the need for manual handling.
Validation Simplified
For pharmaceutical producers, validation is a critical requirement — and freeze drying is no exception. The Active Freeze Dryer supports full compliance with EMA, FDA, cGMP and GAMP regulations. Each batch is processed under tightly controlled, repeatable conditions, with consistent results and comprehensive documentation. This simplifies validation procedures and reduces the time, effort and cost required to bring your process into compliance.
Models & Capacities
Indicative values; performance depends on product properties and process parameters. Detailed specifications available on request.
| Model (AFD) | [L] | 1 | 5 | 20 | 60 | 100 | 200 | 500 | 800 | 1,000 | 1,500 |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Max. batch volume | [L] | 0.5 | 2.5 | 10 | 30 | 50 | 100 | 250 | 400 | 500 | 750 |
| Indicative sublimation capacity | [kg/h] | 0.1 | 0.3 | 0.8 | 1.7 | 2.2 | 3.4 | 7.2 | 9.9 | 11.4 | 13.7 |
| R&D > | GMP manufacturing > | ||||||||||
An Active Freeze Drying system features the following components and functionalities:
- Lyophilisation chamber (product chamber)
- Dust filter to keep the product in the product chamber
- Vacuum pump skid for pressure control
- Temperature Control Unit (TCU) for thermal management
- CIP facilities for automated cleaning
- SIP facilities for sterilisation in place (optional)
- Control system, 21 CFR Part 11 compliant
- Utility Management Skid, interface between AFD and factory utilities
- Customised support / lift
- Features for contained operation
- cGMP documentation package
Bespoke Drying Systems
Hosokawa Micron has over a century of experience in developing advanced solids processing systems. Our engineering expertise ensures every Active Freeze Drying installation is carefully designed, configured and validated to meet the specific needs of your product and production environment. From initial concept to final installation, we work with you to create a fully integrated, high-performance drying solution.
Learn more
Test Before You Invest
At our Test & Process Development Centre in the Netherlands, Hosokawa Micron offers a 'try before you buy' approach for Active Freeze Drying, with unit sizes from 1 to 800 L available for testing and scale-up trials. Our experts work closely with you to develop and optimise the process, ensuring it fits your product and requirements. This collaborative approach combines your product knowledge with our AFD expertise to ensure the perfect fit for your application.
Learn more
Talk to our experts
Let our specialists help you configure the right freeze drying system for your pharmaceutical powders — tailored to your process and optimised for efficiency, safety and product quality.
FAQ – Active Freeze Dryer
What is an Active Freeze Dryer?
How does an Active Freeze Dryer work?
In the AFD, the product is frozen while being agitated in a jacketed chamber. Once fully frozen, a vacuum is applied and sublimation begins. The dynamic motion ensures even heat transfer and consistent drying, resulting in fine, porous granules that can be discharged directly.
What materials can be processed in an Active Freeze Dryer?
The AFD can handle a wide variety of materials, including liquids, suspensions, pastes and wet solids. It is especially suited for high-value pharmaceutical substances such as APIs, antibiotics, collagens and proteins.
What are the advantages of the Active Freeze Dryer?
Compared to traditional tray freeze dryers, the AFD offers faster, cleaner and more consistent processing. It eliminates manual handling, reduces drying time and delivers a uniform, free-flowing powder with excellent redispersibility and flow properties.
What capacities and sizes are available?
The AFD is available in a wide range of sizes, from 5 L to 1,500 L. Lab and pilot models starting at 1 L are also available for R&D and process development. All systems can be customised to meet specific process requirements.
How does the AFD compare to traditional tray freeze drying?
Traditional tray drying requires static freezing, long cycle times, operator intervention and post-processing. The AFD replaces all of this with a closed, fully automated one-pot process — reducing risk, effort and time, while improving product quality and consistency.
Sustainable process technologies
Hosokawa Micron B.V. is committed to sustainable and responsible process technology. Our ISO 14001 certification covers key environmental aspects such as air, soil, energy, waste, water, noise and hazardous substances. With an EcoVadis Silver Medal, we rank among the top 3% of EcoVadis-rated companies in the special machinery industry.
