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A Guide To Freeze Drying for the Laboratory An Industry Service Publication

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Page 1: Freeze Drying Guide

AGuide

ToFreezeDryingfor the

Laboratory

An Industry Service Publication

Page 2: Freeze Drying Guide

2

Page 3: Freeze Drying Guide

Foreword

This booklet has been developed to serve as a basicguide to the freeze drying process. The informationpresented is generic in nature and is the result ofresearch and experience by Labconco personnel andusers of freeze drying equipment. It is our intention toprovide a non-biased review of preparation techniquesand freeze drying methods. The purpose of this booklet isto help you make an informed choice of equipment foryour laboratory applications.

Our Method

We begin our discussion of freeze drying for thelaboratory by examining the three steps in the process:prefreezing, primary drying and secondary drying. Next,we examine a typical freeze drying cycle and the methodsavailable to facilitate the freeze drying process usingequipment designed for use by laboratories. Finally,suggestions to optimize successful results are discussed,including determination of end point, contamination,backfilling of dried samples and product stability. A glossary of terms used throughout this booklet toexplain the freeze drying process follows the text, alongwith a bibliography.

Introduction

Freeze drying has been used in a number ofapplications for many years, most commonly in the foodand pharmaceutical industries. There are, however, manyother uses for the process including the stabilization ofliving materials such as microbial cultures, preservationof whole animal specimens for museum display,restoration of books and other items damaged by water,and the concentration and recovery of reaction products.

Specialized equipment is required to create theconditions conducive to the freeze drying process. Thisequipment is currently available and can accommodatefreeze drying of materials from laboratory scale projectsto industrial production.

Freeze drying involves the removal of water or othersolvent from a frozen product by a process calledsublimation. Sublimation occurs when a frozen liquidgoes directly to the gaseous state without passingthrough the liquid phase. In contrast, drying at ambienttemperatures from the liquid phase usually results inchanges in the product, and may be suitable only forsome materials. However, in freeze drying, the materialdoes not go through the liquid phase, and it allows thepreparation of a stable product that is easy to use andaesthetic in appearance.

The advantages of freeze drying are obvious. Properlyfreeze dried products do not need refrigeration, and can be stored at ambient temperatures. Because the costof the specialized equipment required for freeze dryingcan be substantial, the process may appear to be anexpensive undertaking. However, savings realized bystabilizing an otherwise unstable product at ambienttemperatures, thus eliminating the need forrefrigeration, more than compensate for the investmentin freeze drying equipment.

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Page 4: Freeze Drying Guide

Principles of Freeze Drying

The freeze drying process consists of three stages:prefreezing, primary drying, and secondary drying.

Prefreezing: Since freeze drying is a change in statefrom the solid phase to the gaseous phase, material to befreeze dried must first be adequately prefrozen. Themethod of prefreezing and the final temperature of thefrozen product can affect the ability to successfully freezedry the material.

Rapid cooling results in small ice crystals, useful inpreserving structures to be examined microscopically,but resulting in a product that is more difficult to freeze dry. Slower cooling results in larger ice crystalsand less restrictive channels in the matrix during thedrying process.

Products freeze in two ways, depending on themakeup of the product. The majority of products that aresubjected to freeze drying consist primarily of water, thesolvent, and the materials dissolved or suspended in thewater, the solute. Most samples that are to be freeze driedare eutectics which are a mixture of substances thatfreeze at lower temperatures than the surrounding water.When the aqueous suspension is cooled, changes occurin the solute concentrations of the product matrix. Andas cooling proceeds, the water is separated from thesolutes as it changes to ice, creating more concentratedareas of solute. These pockets of concentrated materialshave a lower freezing temperature than the water.Although a product may appear to be frozen because ofall the ice present, in actuality it is not completely frozenuntil all of the solute in the suspension is frozen. Themixture of various concentration of solutes with thesolvent constitutes the eutectic of the suspension. Onlywhen all of the eutectic mixture is frozen is thesuspension properly frozen. This is called the eutectictemperature.

It is very important in freeze drying to prefreeze theproduct to below the eutectic temperature beforebeginning the freeze drying process. Small pockets ofunfrozen material remaining in the product expand and compromise the structural stability of the freeze dried product.

The second type of frozen product is a suspension thatundergoes glass formation during the freezing process.Instead of forming eutectics, the entire suspensionbecomes increasingly viscous as the temperature islowered. Finally the product freezes at the glasstransition point forming a vitreous solid. This type ofproduct is extremely difficult to freeze dry.

Primary drying: Several factors can affect the abilityto freeze dry a frozen suspension. While these factors canbe discussed independently, it must be remembered thatthey interact in a dynamic system, and it is this delicatebalance between these factors that results in a properlyfreeze dried product.

After prefreezing the product, conditions must beestablished in which ice can be removed from the frozenproduct via sublimation, resulting in a dry, structurallyintact product. This requires very careful control of thetwo parameters, temperature and pressure, involved inthe freeze drying system. The rate of sublimation of icefrom a frozen product depends upon the difference in

vapor pressure of the product compared to the vaporpressure of the ice collector. Molecules migrate from thehigher pressure sample to a lower pressure area. Sincevapor pressure is related to temperature, it is necessarythat the product temperature is warmer than the coldtrap (ice collector) temperature. It is extremelyimportant that the temperature at which a product isfreeze dried is balanced between the temperature thatmaintains the frozen integrity of the product and thetemperature that maximizes the vapor pressure of theproduct. This balance is key to optimum drying. Thetypical phase diagram shown in Figure 1 illustrates thispoint. Most products are frozen well below their eutecticor glass transition point (Point A), and then thetemperature is raised to just below this criticaltemperature (Point B) and they are subjected to areduced pressure. At this point the freeze drying processis started.

Figure 1

A typical phase diagram.

Some products such as aqueous sucrose solutions canundergo structural changes during the drying processresulting in a phenomenon known as collapse. Althoughthe product is frozen below its eutectic temperature,warming during the freeze drying process can affect thestructure of the frozen matrix at the boundary of thedrying front. This results in a collapse of the structuralmatrix. To prevent collapse of products containing

A vacuum pump is essential to evacuate the environment around the product to be freeze dried.

4

SolidPhase

LiquidPhase

VaporPhase

FU

SIO

NLIN

E

VAPORIZAT

ION

LINE

SUBLIMATION LINE

CRITICALPOINT

TRIPLEPOINT

A

B

CD

PR

ES

SU

RE

TEMPERATURE

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Importância da velocidade da pré congelação na formação de canais que posteriormente são importantes na liofilização.
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Etapas da liofilização
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Explicação do que é e das sua importância PONTo EUTÉCTICO
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Importância de congelar abaixo do ponto eutéctico.
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Segundi tipo de formação de gelo e dificulade em liofilizar.
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Importância do balanço entre pressão e temperatura. Explicação da dinâmica de secagem (velocidade de secagem) com a pressão de vapor.
Page 5: Freeze Drying Guide

sucrose, the product temperature must remain below acritical collapse temperature during primary drying. Thecollapse temperature for sucrose is -32° C.

No matter what type of freeze drying system is used,conditions must be created to encourage the free flow ofwater molecules from the product. Therefore, a vacuumpump is an essential component of a freeze dryingsystem, and is used to lower the pressure of theenvironment around the product (to Point C). The otheressential component is a collecting system, which is acold trap used to collect the moisture that leaves thefrozen product. The collector condenses out allcondensable gases, i.e; the water molecules, and thevacuum pump removes all non-condensable gases.

The collecting system acts as a cold trap to collectmoisture leaving the frozen product.

It is important to understand that the vapor pressureof the product forces the sublimation of the water vapormolecules from the frozen product matrix to thecollector. The molecules have a natural affinity to movetoward the collector because its vapor pressure is lowerthan that of the product. Therefore, the collectortemperature (Point D) must be significantly lower thanthe product temperature. As can be noted in Table 1,raising the product temperature has more effect on the vapor pressure differential than lowering thecollector temperature.

Table 1

Vapor Pressure/Temperature Relationships

A third component essential in a freeze drying systemis energy. Energy is supplied in the form of heat. Almostten times as much energy is required to sublime a gramof water from the frozen to the gaseous state as isrequired to freeze a gram of water. Therefore, with allother conditions being adequate, heat must be applied tothe product to encourage the removal of water in theform of vapor from the frozen product. The heat must bevery carefully controlled, as applying more heat than theevaporative cooling in the system can remove warms theproduct above its eutectic or collapse temperature.

Heat can be applied by several means. One method isto apply heat directly through a thermal conductor shelfsuch as is used in tray drying. Another method is to useambient heat as in manifold drying.

Secondary drying: After primary freeze drying iscomplete, and all ice has sublimed, bound moisture isstill present in the product. The product appears dry, butthe residual moisture content may be as high as 7-8%.Continued drying is necessary at the warmertemperature to reduce the residual moisture content tooptimum values. This process is called isothermaldesorption as the bound water is desorbed from the product.

Secondary drying is normally continued at a producttemperature higher than ambient but compatible withthe sensitivity of the product. All other conditions, suchas pressure and collector temperature, remain the same.Because the process is desorptive, the vacuum should beas low as possible (no elevated pressure) and the collectortemperature as cold as can be attained. Secondary dryingis usually carried out for approximately 1/3 to 1/2 thetime required for primary drying.

How Freeze Drying Works

Refer to the phase diagram (Figure 1) and a typicalsublimation cycle (Figure 2). The product is first cooledto below its eutectic temperature (Point A). The collectoris cooled to a temperature approximately 20° C coolerthan the product temperature, generally around -50 to -80° C. The product should be freeze dried at atemperature slightly lower than its eutectic or collapsetemperature (Point B) since the colder the product, thelonger the time required to complete primary drying, andthe colder the collector temperature required toadequately freeze dry the product.

After the product is adequately frozen and thecollector temperature achieved, the system is evacuatedusing a vacuum pump (Point C). At this point, primarydrying of the product begins and continues until theentire frozen matrix appears dry. Heat input to theproduct may be achieved by several means such asincreasing the shelf temperature in the case of traydrying, or using a liquid bath for manifold drying. Whilethe collector and vacuum pump create the conditions forallowing sublimation to occur, heat input is really thedriving force behind the whole process.

Heat input to the sample can be enhanced bycontrolling the pressure in the system at some levelabove the ultimate capability of the vacuum pump. Some

Vapor Pressure (mBar) Temperature (°C)6.104 02.599 -101.034 -200.381 -300.129 -400.036 -500.011 -600.0025 -700.0005 -80

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Condições de condensação da água e gases não condensáveis.
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Temperatura do colector da água e temperatura do produto a secar. Força motriz em causa.
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Importância da regulação da temperatura do produto na eficácia da liofilização. Ultrapassar a temperatura de colapso e eutéctico.
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Humidade ligada
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Condições da Secagem secundária
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Explicação pormenorizada do procedsso de liofilização.
Page 6: Freeze Drying Guide

freeze dryers incorporate vacuum control systems thatautomatically regulate the pressure to the preset level.This allows additional gas molecules to reside in thesystem thereby improving the conduction of heat to thesample. This improves the sublimation rate, reducingprocess time and associated energy costs. Care must betaken to prevent the pressure within the system fromexceeding the ice vapor pressure of the product ormelting of the sample may occur.

Figure 2

Typical Sublimation Cycle found in system utilizing Tray Dryer with shelves.

Heat input to the product must be very carefullycontrolled especially during the early stages of drying.The configuration of the product container and thevolume of the contained product can affect the amount ofheat that can be applied. For small volumes of material,evaporative cooling compensates for high levels of heatand drying is accelerated.

The volume and configuration of the suspension to befreeze dried often determines how the material is freezedried. For example, the greater the ratio of the surfacearea to the volume of the suspension, the faster dryingoccurs. This is because a greater area for the watermolecules to leave the product exists compared to thedistance they have to travel to reach the surface of thefrozen matrix. Drying occurs from the top of the productand initially the removal of water molecules is efficient.However, as the drying front moves down through the

Figure 3

Ambient room temperature provides heat to encourage removal of water vapor from frozen samples whenmanifold drying.

product, drying becomes more and more difficult. Thewater molecules must now travel through the driedportions of the product which impedes their progress. Asthe drying front moves farther and farther down thematrix, the application of heat to the product becomesmore important (Figure 3).

Shell freezing as a method of prefreezing the productcan increase the surface area to volume ratio byspreading out the frozen product inside the vessel(Figure 4). Shell freezing is accomplished by rotating thevessel in a low temperature bath causing the product tofreeze in a thin layer on the inside surface of the vessel.The thickness of the frozen suspension depends on thevolume of the product in comparison to the size of thevessel. Shell freezing is primarily used in conjunctionwith manifold drying.

The vacuum system is very important during freezedrying because the pressure must be maintained at a lowlevel to ensure adequate water vapor flow from theproduct to the collector. A pressure gauge (commonlycalled a vacuum gauge) is used to monitor the pressurein the system during the drying process. Pressure can beexpressed in several different units which are comparedin Table 2. Some gauges measure condensable gases,while others do not. Those gauges that do not measurethe condensable gases give an indication of the totalpressure in the system. Gauges that do sense thecondensable gases indicate a change in pressure duringdrying. These sensors can be used as an indication of the rate of drying, as well as the endpoint of the drying process.

Figure 4

Shell freezing can increase the surface area to volume ratio by spreading out the frozen product inside the vessel.

Table 2

Pressure Relationships

6

A

B

C

D

As drying proceeds producttemperature remains below

shelf temperature

When primary drying is completeproduct temperature equals

shelf temperature

ERUTAREPMET

RESNEDNOC

ERUTAREPMETTCUDORP

ERUTAREPMETFLEHS

TIME

PR

ES

SU

RE

TE

MP

ER

AT

UR

E

WaterVapor

Dry Cake

Frozen Sample

Interface

Build-up of FrozenMaterial

Microns mm Hg Torr mBar1000 1 1 1.33100 0.1 0.1 0.13310 0.01 0.01 0.03

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Técnica não importante para o nosso projecto. Aplicada masi a liofilização de amostras biológicas, tipo tubo de ensaio.
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Explicação pormenorizada do procedsso de liofilização.
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Manómetros de pressão total e manómetros de pressaõ de GASES CONDENSÁVEIS, indicam velocidades de secagem e pontos do processo, importantes na detecão da paragem da secagem.
Page 7: Freeze Drying Guide

Freeze Drying Methods

Three methods of freeze drying are commonly used:(1) manifold drying, (2) batch drying, and (3) bulkdrying. Each method has a specific purpose, and themethod used depends on the product and the finalconfiguration desired.

Manifold Method. In the manifold method, flasks,ampules or vials are individually attached to the ports ofa manifold or drying chamber. The product is eitherfrozen in a freezer, by direct submersion in a lowtemperature bath, or by shell freezing, depending on thenature of the product and the volume to be freeze dried.The prefrozen product is quickly attached to the dryingchamber or manifold to prevent warming. The vacuummust be created in the product container quickly, and theoperator relies on evaporative cooling to maintain thelow temperature of the product. This procedure can onlybe used for relatively small volumes and products withhigh eutectic and collapse temperatures.

Manifold drying has several advantages over batch traydrying. Since the vessels are attached to the manifoldindividually, each vial or flask has a direct path to thecollector. This removes some of the competition formolecular space created in a batch system, and is mostideally realized in a cylindrical drying chamber where thedistance from the collector to each product vessel is thesame. In a “tee” manifold, the water molecules leavingthe product in vessels farthest from the collectorexperience some traffic congestion as they travel past theports of other vessels.

In the manifold drying method, flasks are individually attached to the ports of a drying chamber.

Heat input can be affected by simply exposing thevessels to ambient temperature or via a circulating bath.For some products, where precise temperature control isrequired, manifold drying may not be suitable.

Several vessels can be accommodated on a manifoldsystem allowing drying of different products at the sametime, in different sized vessels, with a variety of closuresystems. Since the products and their volumes may differ,each vessel can be removed from the manifold separatelyas its drying is completed. The close proximity to thecollector also creates an environment that maximizesdrying efficiency.

Batch Method. In batch drying, large numbers ofsimilar sized vessels containing like products are placedtogether in a tray dryer. The product is usually prefrozenon the shelf of the tray dryer. Precise control of theproduct temperature and the amount of heat applied tothe product during drying can be maintained. Generallyall vials in the batch are treated alike during the dryingprocess, although some variation in the system canoccur. Slight differences in heat input from the shelf canbe experienced in different areas. Vials located in thefront portion of the shelf may be radiantly heatedthrough the clear door. These slight variations can resultin small differences in residual moisture.

Batch drying allows closure of all vials in a lot at thesame time, under the same atmospheric conditions. Thevials can be stoppered in a vacuum, or after backfillingwith inert gas. Stoppering of all vials at the same timeensures a uniform environment in each vial and uniformproduct stability during storage. Batch drying is used toprepare large numbers of ampules or vials of one productand is commonly used in the pharmaceutical industry.

Batch drying in a tray dryer permits precise control of product temperature and heat input.

Bulk Method. Bulk drying is generally carried out in a tray dryer like batch drying. However, the product ispoured into a bulk pan and dried as a single unit.Although the product is spread throughout the entiresurface area of the shelf and may be the same thicknessas product dried in vials, the lack of empty spaces withinthe product mass changes the rate of heat input. Theheat input is limited primarily to that provided bycontact with the shelf as shown in Figure 5.

Bulk drying does not lend itself to sealing of productunder controlled conditions as does manifold or batchdrying. Usually the product is removed from the freezedry system prior to closure, and then packaged in air tight containers. Bulk drying is generally reserved forstable products that are not highly sensitive to oxygen or moisture.

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Page 8: Freeze Drying Guide

Figure 5

In bulk drying, heat is provided primarily through conduction from shelf.

Determining Drying Endpoints

Several means can be used to determine the endpointof primary drying. The drying boundary in batch dryingcontainers has moved to the bottom of the productcontainer and inspection reveals that no ice is visible inthe product. No visible ice indicates only that drying atthe edges of the container is complete and gives noindication of the conditions in the center of the product.An electronic vacuum gauge can be used to measurecondensable gases in the system. When the pressureindicated by the electronic gauge reaches the minimumpressure attainable by the system, as measured by using aMcLeod vacuum gauge or as determined previously, nomore water vapor is leaving the product.

As the heat input to the product is increased,evaporative cooling keeps the product temperature wellbelow the temperature of its surrounding atmosphere.When primary drying is complete, the producttemperature rises to equal the temperature of itsenvironment. In manifold systems and tray dryers withexternal collectors, the path to the collector can be shutoff with a valve and the pressure above the productmeasured with a vacuum gauge. If drying is stilloccurring, the pressure in the system increases.

Contamination in a Freeze Dry System

Two types of contamination can occur in a freeze drysystem. One results from freeze drying microorganismsand the other results from freeze drying corrosivematerials.

The potential for contamination of a freeze dryingsystem by microorganisms is real in any system wheremicroorganisms are freeze dried without a protectivebarrier such as a bacteriological filter. Contamination is

most evident in batch tray dryer systems where largenumbers of vials are dried in a single chamber. Evidencefor contamination can be found by sampling the surfacesof the vials, shelves and collector. The greatest degree ofcontamination is usually found on the vials and on thecollector. Some vial contamination can be due to a bit ofsloppiness in dispensing the material originally, butcontamination on the collector is due to microorganismstraveling from the product to the collector through thevapor stream.

The potential for contamination must be consideredevery time microorganisms are freeze dried, andprecautions must be taken in handling material after thefreeze dry process is completed. Recognizing that thevials are potentially contaminated, the operator shouldremove the vials to a safe area such as a laminar flowhood for decontamination. Decontamination of the freezedry system depends upon the type of freeze dry systemused. Some tray dryer systems are designed fordecontamination under pressure using ethylene oxidesterilization. Ethylene oxide is considered hazardous,corrosive and detrimental to rubber components. Its useshould be carefully monitored.

Coupled with the risk of contamination in a freeze drysystem is the risk of cross contamination when freezedrying more than one product at time. It is not a goodpractice to mix microbiological products in a freeze drysystem unless some type of bacteriological filter is used to prevent the microbial product from leaving thevial itself.

While freeze drying of corrosive materials does notnecessarily present a risk to the operator, it does presenta risk of damaging the freeze dry system itself. Freeze drysystems are designed using materials that resistcorrosion and prevent the build up of corrosive materials.But care should be taken to clean the system thoroughlyfollowing each use to protect it from damage.

Backfilling

For many freeze dried products, the most ideal systemof closure is while under vacuum. This provides anenvironment in which moisture and oxygen, bothdetrimental to the freeze dried material, are preventedfrom coming in contact with the product. In some cases,vacuum in a container may be less than ideal, especiallywhen a syringe is used to recover the product, or whenopening the vessel results in a rush of potentiallycontaminating air. In these cases, backfilling the productcontainer with an inert gas such as argon or nitrogen isoften beneficial. The inert gas must be ultrapure,containing no oxygen or moisture.

Backfilling of the product container is generally usefulin a batch tray dryer type system. The backfilling shouldalso be carried out through a bacteriological filter. It isimportant that the gas flow during backfilling be slowenough to allow cooling of the gas to prevent raising thecollector temperature. Backfilling can be carried out toany desired pressure in those tray dryers that haveinternal stoppering capability, and the vials thenstoppered at the desired pressure.

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������Some heat input at

edges where dryingoccurs faster than

in middle

Page 9: Freeze Drying Guide

Stability of Freeze Dried Products

Several factors can affect the stability of freeze dried material. Two of the most important are moistureand oxygen.

All freeze dried products have a small amount ofmoisture remaining in them termed residual moisture.The amount of moisture remaining in the materialdepends on the nature of the product and the length ofsecondary drying. Residual moisture can be measured byseveral means: chemically, chromatographically,manometrically or gravimetrically. It is expressed as aweight percentage of the total weight of the driedproduct. Residual moisture values range from <1% to 3%for most products.

By their nature, freeze dried materials are hygroscopicand exposure to moisture during storage can destabilizethe product. Packaging used for freeze dried materialsmust be impermeable to atmospheric moisture. Storingproducts in low humidity environments can reduce therisk of degradation by exposure to moisture. Oxygen isalso detrimental to the stability of most freeze driedmaterial so the packaging used must also beimpermeable to air.

The detrimental effects of oxygen and moisture aretemperature dependent. The higher the storagetemperature, the faster a product degrades. Most freezedried products can be maintained at refrigeratortemperatures, i.e. 4-8° C. Placing freeze dried products atlower temperatures extends their shelf life. The shelf lifeof a freeze dried product can be predicted by measuringthe rate of degradation of the product at an elevatedtemperature. This is called accelerated storage. Bychoosing the proper time and temperature relationshipsat elevated temperatures, the rate of product degradationcan be predicted at lower storage temperatures.

Contact Labconco for a complimentary catalog of Freeze Dry Systems designed for laboratory use.

The Labconco catalog provides additional informationabout freeze drying equipment. It is available uponrequest from your laboratory supply dealer or LabconcoCorporation at (800) 821-5525, (816) 333-8811 orwww.labconco.com.

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Glossary

Accelerated Storage: Exposure of freeze dried products toelevated temperatures to accelerate the degradation process thatoccurs during storage.

Batch Freeze Drying: Freeze drying multiple samples of thesame product in similar sized vessels at the same time in a shelftray dryer.

Bulk Freeze Drying: Freeze drying a large sample of a singleproduct in one vessel such as the bulk drying pans designed forshelf tray dryers.

Collapse: A phenomenon causing collapse of the structuralintegrity of a freeze dried product due to too high a temperatureat the drying front.

Collapse Temperature: The temperature above which collapse occurs.

Collector: A cold trap designed to condense the water vaporflowing from a product undergoing freeze drying.

Internal Collector: A collector located in the same area as theproduct. All water vapor has a free path to the collector.

External Collector: A collector located outside the productarea connected by a small port through which all water vapormust pass. Allows isolation of the product from the collectorfor drying end point determinations and easier defrosting.

Ethylene Oxide: A colorless, odorless gas used for gassterilization of tray dryer systems.

Eutectics: Areas of solute concentration that freeze at a lowertemperature than the surrounding water. Eutectics can occur atseveral different temperatures depending on the complexity ofthe product.

Eutectic Temperature: The temperature at which all areas ofconcentrated solute are frozen.

Evaporative Cooling: Cooling of a liquid at reduced pressurescaused by loss of the latent heat of evaporation.

Freeze Drying: The process of drying a frozen product bycreating conditions for sublimation of ice directly to water vapor.

Glass Transition Temperature: The temperature at whichcertain products go from a liquid to a vitreous solid without icecrystal formation.

Isothermal Desorption: The process of desorbing water from afreeze dried product by applying heat under vacuum.

Lyophilization: The freeze drying process.

Manifold Freeze Drying: A freeze drying process where eachvessel is individually attached to a manifold port resulting in adirect path to the collector for each vessel.

Prefreezing: The process of cooling a product to below itseutectic temperature prior to freeze drying.

Pressure Gauge (Vacuum Gauge): An instrument used tomeasure very low pressures in a freeze drying system.

Thermocouple Gauge: A pressure gauge that measures onlythe condensable gases in the system. This gauge can be usedas an indicator of drying end points.

McLeod Gauge: A mercury gauge used to measure totalpressure in the system (i.e. condensable and non-condensable gases.)

Primary Drying: The process of removing all unbound water that has formed ice crystals in a product undergoingfreeze drying.

Residual Moisture: The small amount of bound water thatremains in a freeze dried product after primary drying. Residualmoisture is expressed as the weight percentage of waterremaining compared to the total weight of the dried product.The amount of residual moisture in a freeze dried product canbe reduced during secondary drying.

Secondary Drying: The process of reducing the amount ofbound water in a freeze dried product after primary drying iscomplete. During secondary drying, heat is applied to theproduct under very low pressures.

Shell Freezing: Freezing a product in a thin layer that coats theinside of the product container. Shell freezing is accomplishedby swirling or rotating the product container in a lowtemperature bath.

Sublimation: The conversion of water from the solid state (ice)directly to the gaseous state (water vapor) without goingthrough the liquid state.

Vapor Pressure: The pressure of the vapor in equilibrium withthe sample.

Page 11: Freeze Drying Guide

Bibliography

1. Barbaree, J.M. and A. Sanchez. 1982. Cross-contaminationduring lyophilization. Cryobiology 19:443-447.

2. Barbaree, J.M., A. Sanchez and G.N. Sanden. 1985.Problems in freeze-drying: I. Stability in glass-sealed rubber stoppered vials. Developments in IndustrialMicrobiology 26:397-405.

3. Barbaree, J.M., A. Sanchez and G.N. Sanden. 1985. Problems in freeze-drying: II. Cross-contamination during lyophilization. Developments in IndustrialMicrobiology 26:407-409.

4. Flink, J.M. and Knudsen, H. 1983. An Introduction toFreeze Drying. Strandberg Bogtryk/Offset, Denmark.

5. Flosdorf, E.W. 1949. Freeze-Drying. Reinhold PublishingCorporation, New York.

6. Greiff, D. 1971. Protein structure and freeze-drying: theeffects of residual moisture and gases. Cryobiology 8:145-152.

7. Greiff, D. and W.A. Rightsel. 1965. An accelerated storagetest for predicting the stability of suspensions of measlesvirus dried by sublimation in vacuum. Journal ofImmunology 94:395-400.

8. Greaves, R.I.N., J. Nagington, and T.D. Kellaway. 1963.Preservation of living cells by freezing and by drying.Federation Proceedings 22:90-93.

9. Harris, R.J.C., Ed. 1954. Biological Applications of Freezingand Drying. Academic Press, New York.

10. Heckly, R.J. 1961. Preservation of bacteria by lyophilization.Advances in Applied Microbiology 3:1-76.

11. Heckly, R.J. 1985. Principles of preserving bacteria by freeze-drying. Developments in Industrial Microbiology26:379-395.

12. King, C.J. 1971. Freeze-Drying of Foods. CRC Press,Cleveland.

13. May, M.C. E. Grim, R.M. Wheeler and J. West. 1982.Determination of residual moisture in freeze-dried viral vaccines: Karl Fischer, gravimetric, andthermogravimetric methodologies. Journal of BiologicalStandardization 10:249-259.

14. Mellor, J.D. 1978. Fundamentals of Freeze-Drying.Academic Press, London.

15. Nail, S.L. 1980. The effect of chamber pressure on heattransfer in the freeze-drying of parental solutions. Journal of the Parental Drug Association 34:358-368.

16. Nicholson, A.E. 1977. Predicting stability of lyophilized products. Developments in BiologicalStandardization 36:69-75.

17. Parkes, A.S., and A.U. Smith, Eds. 1960. Recent Research in Freezing and Freeze-Drying. Charles C. Thomas,Springfield.

18. Rey, L.R., Ed. 1960. Traite de Lyophilization.Hermann, Paris.

19. Rey, L.R., Ed. 1964. Aspects Theorique et Industriels de laLyophilisation. Hermann, Paris.

20. Rowe, T.W.G. 1970. Freeze-drying of biological materials:some physical and engineering aspects. Current Trends inCryobiology: 61-138.

21. Seligman, E.B. and J.F. Farber. 1971. Freeze-drying andresidual moisture. Cryobiology 8:138-144.

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