Freeze Drying

Theory
Removal of water from foods by sublimation. No transitional liquid phase.Vapor pressure and temperature are below triple point Food is conventionally frozen Small pieces are frozen rapidly Produces small crystals Liquid products are frozen slowly Produces an ice crystal lattice Allows for movement of water vapor

The triple point of water

+The triple point is the one condition where three phases-solid ice, liquid water, and water vapor-coexist at equilibrium. + Frozen foods are subjected lower pressure(4.58 Torr = 610.5 Pa) 1atmosphere = 760 Torr = 101325Pa when the food is heated the ice sublimes.

Theory

Foods are dried in 2 stages 1st stage by sublimation Usually to 15% wb 2nd stage by evaporative (desorption) drying To a MC of 2% wb Desorption achieved by raising the temperature in the drier to near ambient temperature whilst retaining the low pressure.

Heat transfer
There are three methods of transferring heat to the sublimation front: 1) Heat transfer through the frozen layer. The rate of heat transfer depends on the thickness and thermal conductivity of the ice layer. 2) Heat transfer through the dried layer . The rate of heat transfer to the sublimation front depend on the thickness and area of the food, the thermal conductivity of the dry layer and the temperature difference between the surface of the food and ice front. Heating by microwaves . Heat is generated at the ice front, and threat of heat transfer is not influenced by the thermal conductivity of ice or dry foods, or the thickness of the dry layer.

(3)

Heat transfer

Heat transfer and moisture transfer during freeze drying, (a) heat transfer Through the frozen layer (b) heat transfer from hot surface through the dry layer ( c) heat generated in the ice by microwaves. The graph show changes in temperature (---) and moisture content( ) along the line ABC through each sample.

Rate of Mass transfer

The factors that control the water vapour pressure gradient: (1) The pressure in the drying chamber, (2) The temperature of the vapour condenser, both of which should be as low as economically possible, and (3) The temperature of ice at the sublimation front, which should be as high as possible, without melting. In practice, the lowest economical chamber pressure is approximately 13 Pa and the lowest condenser temperature is approximately -35C.

Equipment
Freeze driers consist of a vacuum chamber which contains trays to hold the food during drying, and heaters to supply latent heat of sublimation. Refrigeration coils are used to condense the vapours
Efficiency = Temperature of sublimation Refrigerant temperature in the condenser

Characterized by method used to supply heat to surface of food

Conduction Convection

Radiation
_ Microwave freeze drying is under development

Continuous freeze drying

In continuous freeze drying, trays of food enter and leave the drier through vacuum locks. A stack of trays, interspersed by heater plate is moved on guide rails through heating zones in a long vacuum chamber.

Continuous freeze-drying system with up to 60 tons of fresh product per day per unit

Contact freeze driers

Food is placed onto ribbed trays which rest on heater plates . This type of equipment dries more slowly than other designs because heat is transferred, by conduction, to one side of the food.

Freezing drying methods a) conduction through ribbed tray; (b) expanded mesh for accelerated freeze drying; (c) radiant heating of flat trays.

Freeze Drying Plant of Continuous Radiation type

The CONRAD (Continuous Radiation) freeze drying plant is fully automatic and controlled centrally. By means of the conveyor system the trays pass into the filling station where the frozen product is dosed into the tray. The trays proceed through the inlet airlock and into the inlet elevator. When the elevator is filled to its capacity of 15 trays, the whole stack is pushed into the first temperature zone. Subsequently, the stack of 15 trays is pushed by the following stacks through the various zones, each adjusted to give the product the optimal heat treatment. Finally, the stack arrives at the exit elevator, and the trays are led through the exit airlock to the emptying station where the now freeze-dried product is removed. After being washed, the empty trays return automatically to the filling station to repeat the process.

Technology
A freeze-drying machine works by simulating these conditions. A freeze-drying machine consists of: A freeze-drying chamber with several shelves attached to heating units, a freezing coil connected to a refrigerator compressor, and a vacuum pump .

Technology
While the material to be freeze-dried is sill unfrozen, you place is on to the shelves. Then you seal the chamber and begin the process.The machine runs compressor to lower the temperature in the chamber. the material freezes solid. On the molecular level, the water in the material is separated from everything around it even though it is still present (Harris 2).

Technology
Water condenses here

Then the vacuum pump to forces air out of the chamber so that the atmospheric pressure is lowered to below .06 atm. The heating units supply some heat to the shelves so that the ice changes phases. Because the pressure is so low, the ice turns into water vapor without passing through the liquid phase. The water vapor flows out of the chamber, past the freezing coil where it condenses in ice form (Harris 2).

Advantages
The principle advantages of lyophilization as a drying process are: - Minimum damage and loss of activity in delicate heat-liable materials - Speed and completeness of rehydration - Possibility of accurate, clean dosing into final product containers - Porous, friable structure

Disadvantages
The principle disadvantages of lyophilization are: - High capital cost of equipment (about three times more than other methods) - High energy costs (2-3 times more than other methods) - Long process time (typically 24 hour drying cycle)

Applications
Freeze-drying has lots of applications: Food Flowers Restoration of Water Damaged Materials Pharmaceuticals Biological Samples Weaponized Bacteria

Freeze drying in food

Freeze dried coffee

In 1938 Nestle company invented freeze-dried coffee in response to Brazils request for help in solving the dilemma of surplus coffee beans. Today, we know this product as Nescafe. Since then, freeze drying has been used to preserve all sorts of foods .

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