Lyophilization or freeze drying is a process in which water is removed from a product after it is frozen and placed under a vacuum, allowing the ice to change. For composing validation protocol of lyophilizer need to carry out its qualification test and. decide acceptance criteria. So during selection of. Hi all, I have a question regarding an OQ of a freeze dryer. Im Validation Manager in a medium size medical devices company and have the.

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In addition to the free ice that is sublimed during primary drying, there remains a substantial amount of water molecules that are bound to the product.

TrackSense Pro Data Loggers. The difference in particulates can greatly affect product freezing and ice crystal size. Wireless Data Logger Accessories:. Additionally, the chamber must lyophilizdr L stainless steel. Product chambers are typically either a manifold with attached flasks, or, a larger chamber with a system of shelves on which to place the product.

Validation Equipment – Lyophilizer Qualifications

This heat input does not melt the product because an equivalent amount of heat is removed by vaporization of the solvent. Freeze drying is the removal of ice or other frozen solvents from a material through the process of sublimation and the removal of bound water molecules through the process of desorption.

With manifold freeze drying, the process is driven by the system pressure set point and the ambient temperature in the room. Typically, vacuum levels for freeze drying are between 50mTorr and mTorr with mTorr to mTorr being the most common range. In addition to designing a recipe that successfully dries a product, it is also extremely valuable to optimize shorten the length of the cycle, especially if there is potential for process repetition or scale-up for production.

A recommended approach is to first set the system pressure using the vapor pressure of ice table. The process should be repeatable with well defined temperature, pressure and time parameters for each step. An isolation valve can be added to the vapor port that connects the product chamber to the condenser.


Freeze Drying / Lyophilization Information: Basic Principles

The condenser temperature qualificaiton is dictated by the freezing point and collapse temperature of the product. Do not use siliconized stoppers in the lyophilizer. Options include standard laboratory qualificahion, shell baths, and direct immersion in liquid nitrogen. Certain products with high resistance to vapor flow in the dried portion of the cake may require that the shelf temperature be reduced towards the end of primary drying to keep the product temperature at its target and to avoid collapse.

If you have one that is excellent. Product trays with removable-bottoms are available when working with vials. OVERVIEW Freeze drying is the removal of ice or other frozen solvents from a material through the process of sublimation and the removal of bound water molecules through the process of desorption. Annealing has the added advantage of larger crystal growth and corresponding shorter drying times. SP Scientific service professionals are highly knowledgeable and are lyophilizdr to support every instrument, software and application product that SP Scientific has brought to the market.


System vacuum may be continued at the same level used during primary drying; lower vacuum levels will not improve secondary drying times. Determination of the critical collapse temperature of a product is an important step in establishing and optimizing a freeze drying process.

Control systems vary in complexity and usually include temperature and pressure sensing ability. If drying in vials, it is good practice to insert the thermocouple in a vial located in the middle of the shelf. Our people make the difference. Similarity in heat transfer characteristics and shelf temperature uniformity is important to ensure that a lyophilization process developed in the lab can be successfully transferred to a production freeze dryer.


Production freeze dryers are usually configured for operation in a clean room environment and can have the ability for clean-in-place CIP and steam sterilization SIP. NPT Thread to 1.

This valve can be closed for a short period of time and the subsequent rise in pressure in the product chamber can be measured. Because shelf contact is often inconsistent, convective heat transfer can help promote uniform product drying.

A suitable container system must be chosen for the product. Controlled freeze drying keeps the product qualkfication low enough during the process to avoid changes in the dried product appearance and characteristics. It is not recommended to arbitrarily and repetitively increase the shelf temperature during primary drying, as is seen on some older legacy cycles.

Operational Qualification In addition to the common requirements outlined in the “General” section, the OQ protocol will outline the following tests. Thermocouple based unit Option to use your own thermocouples, or purchase thermocouples ready to go from Ellab.

This freezing method maximizes the product surface area and minimizes its thickness. Depending on the application, moisture content in fully dried products is typically between 0. The refrigeration system can also be employed to cool shelves in the product chamber for the freezing of the product. It is good practice to characterize the collapse temperature for all new injectable or ingestible drug formulations to be freeze dried.

In shelf freeze dryers, the condenser can be located inside the product chamber internal condenser or in a separate chamber external condenser connected to the product chamber by a lyoophilizer port. The collapse temperature of amorphous products is typically a few degrees warmer than its glass transition temperature.