BULK FREEZE DRYING USING SPRAY FREEZING AND STIRRED DRYING
First Claim
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1. A freeze drying system for freeze drying bulk product by removing a liquid, comprising:
- a freeze drying chamber for containing product during the freeze drying process;
at least one bulk product spray nozzle connected to a source of the bulk product, the at least one bulk product spray nozzle being directed to an interior of the freeze drying chamber for spraying the bulk product into the freeze drying chamber;
at least one freezing agent spray nozzle connected to a source of a freezing agent, the at least one freezing agent spray nozzle being directed to the interior of the freeze drying chamber for spraying the freezing agent into the freeze drying chamber, the at least one bulk product spray nozzle and the at least one freezing agent spray nozzle being further directed to comingle respective sprays in the interior of the freeze drying chamber to create a spray-frozen product;
a mechanical agitating mechanism in a lower portion of the freeze drying chamber for agitating spray-frozen product accumulated in the lower portion of the chamber to move particles of the product into contact with walls of the freeze drying chamber;
a heater for heating at least lower walls of the freeze drying chamber;
a condensing chamber in communication with the freeze drying chamber and comprising surfaces for condensing a vapor from exhaust gas received from the freezer drying chamber;
a vacuum pump in communication with the condensing chamber; and
a controller comprising memory storing a program that, when executed by the controller, causes the freeze drying system to perform;
an aseptic spray freezing cycle wherein bulk product is sprayed from the at least one bulk product nozzle in the freeze drying chamber and a freezing agent is sprayed from the at least one freezing agent spray nozzle in the freeze drying chamber, to produce a spray frozen powder in the freeze drying chamber; and
an aseptic vacuum freeze drying cycle wherein the vacuum pump evacuates the condensing chamber and the freeze drying chamber, the heater heats the lower walls of the freeze drying chamber and the rotary mechanical agitating mechanism is rotated to dry the spray frozen powder.
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Accused Products
Abstract
A freeze dryer processes bulk powder products. The freeze dryer freezes the product by mixing an atomized spray of product with sterile liquid nitrogen. The resultant powder is freeze dried in a vessel, and the vessel contents is agitated to maintain product contact with heated vessel wall and to prevent agglomeration.
15 Citations
32 Claims
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1. A freeze drying system for freeze drying bulk product by removing a liquid, comprising:
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a freeze drying chamber for containing product during the freeze drying process; at least one bulk product spray nozzle connected to a source of the bulk product, the at least one bulk product spray nozzle being directed to an interior of the freeze drying chamber for spraying the bulk product into the freeze drying chamber; at least one freezing agent spray nozzle connected to a source of a freezing agent, the at least one freezing agent spray nozzle being directed to the interior of the freeze drying chamber for spraying the freezing agent into the freeze drying chamber, the at least one bulk product spray nozzle and the at least one freezing agent spray nozzle being further directed to comingle respective sprays in the interior of the freeze drying chamber to create a spray-frozen product; a mechanical agitating mechanism in a lower portion of the freeze drying chamber for agitating spray-frozen product accumulated in the lower portion of the chamber to move particles of the product into contact with walls of the freeze drying chamber; a heater for heating at least lower walls of the freeze drying chamber; a condensing chamber in communication with the freeze drying chamber and comprising surfaces for condensing a vapor from exhaust gas received from the freezer drying chamber; a vacuum pump in communication with the condensing chamber; and a controller comprising memory storing a program that, when executed by the controller, causes the freeze drying system to perform; an aseptic spray freezing cycle wherein bulk product is sprayed from the at least one bulk product nozzle in the freeze drying chamber and a freezing agent is sprayed from the at least one freezing agent spray nozzle in the freeze drying chamber, to produce a spray frozen powder in the freeze drying chamber; and an aseptic vacuum freeze drying cycle wherein the vacuum pump evacuates the condensing chamber and the freeze drying chamber, the heater heats the lower walls of the freeze drying chamber and the rotary mechanical agitating mechanism is rotated to dry the spray frozen powder. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 31, 32)
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14. A freeze drying system for freeze drying bulk product by removing a liquid, comprising:
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a freezing chamber for containing product during the freezing process; a plurality of spray nozzles configured for comingling sprays of the bulk product and a freezing agent inside the freezing chamber to produce a bulk spray-frozen product powder; a plurality of drying chambers; a plurality of selectively closeable conduits connecting the freezing chamber with the drying chambers, the conduits being configured to transfer the bulk spray-frozen product powder without using trays and shelves; each drying chamber comprising; an agitating mechanism in a lower portion of the drying chamber for agitating spray frozen product powder in the lower portion of the chamber; and a heater for heating at least lower walls of the drying chamber; at least one condensing chamber, each one of the plurality of drying chambers being in communication with at least one of the condensing chambers, the condensing chambers comprising surfaces for condensing a vapor from exhaust gas received from the drying chambers; and a vacuum pump in selective communication with the drying chambers and the condensing chamber. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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21. A method for freeze drying a bulk product containing a liquid, comprising:
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spraying the bulk product into a freezing vessel; spraying a freezing agent into the freezing vessel, the freezing vessel being at a first pressure;
the freezing agent intermingling with the sprayed bulk product to freeze the liquid contained in the bulk product to form a frozen powder before the product drops to a lower portion of the freezing vessel;without transferring the frozen powder, subjecting the freezing vessel to a vacuum pressure lower than the first pressure; agitating the frozen powder under vacuum using the mechanical agitating mechanism; after subjecting the freezing vessel to the vacuum pressure, heating the frozen powder to cause sublimation of frozen liquid in the bulk product to form a freeze dried product; and returning the freeze dried product to atmospheric pressure. - View Dependent Claims (22, 25, 26, 27, 28, 29, 30)
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23. (canceled)
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24. (canceled)
Specification