A REVOLUTION IN COLD DRYING
In 2017, Lyophitech reinvented cold drying with a dynamic freeze-drying solution..
Our innovation
Technological excellence in the service of healthcare
Freeze-drying is a low-temperature, vacuum-based drying process that removes the solvent whilst preserving the molecules, structures and properties of even the most sensitive products. Water or solvent is removed by sublimation, i.e. by passing directly from a solid to a gaseous state, without a liquid phase. The vapours are then captured and condensed in a condenser maintained at a very low temperature.
For over 80 years, this process has been carried out according to a principle that has remained virtually unchanged: the product is frozen and then dried statically on trays arranged within a freeze-drying chamber. However, this traditional design has several limitations: limited heat transfer, long cycle times, poor homogeneity between products, and difficulties in scaling up from the laboratory to industrial production.
Lyophitech is completely rethinking this approach.
Our patented technology is based on a fundamental principle: separating the flash-freezing and sublimation stages in order to optimise each one independently.
Flash-freezing is carried out instantly using liquid nitrogen, ensuring a very high cooling rate.
Our patented technology is based on a fundamental principle: separating the flash-freezing and sublimation stages in order to optimise each one independently.
Freezing is carried out instantly using liquid nitrogen, ensuring a very high cooling rate. This ultra-rapid freezing limits the growth of ice crystals, preserves fragile structures and maintains microscopic organisations, particularly for nanoparticles, biomolecules, polymers and complex formulations.
Once flash-frozen, the product is transferred to a dynamic sublimator (patented) where it is set in rotary motion under vacuum for the entire duration of the drying process. This constant agitation continuously renews the exchange surfaces and significantly improves heat and mass transfer, naturally accelerating sublimation.
Vapour condensation is achieved by a liquid nitrogen condenser connected to the sublimator, allowing the drying and condensation functions to be separated and providing a much more flexible industrial design.
The benefits of Lyophitech technology
This dynamic approach ushers in a new generation of freeze-drying processes:
Significantly reduced drying cycles thanks to optimised heat transfer.
Enhanced preservation of sensitive products thanks to ultra-rapid freezing.
Excellent drying homogeneity across the entire batch.
Inherent scalability, from the laboratory to industrial production, whilst maintaining the same physical mechanisms.
Easier processing of powders, granules, suspensions, nanoparticles and complex formulations.
Reduced energy consumption thanks to improved process efficiency.
Modular industrial architecture allowing flexible integration into production lines.
More than just an evolution of the traditional freeze-dryer, Lyophitech introduces a new paradigm: dynamic freeze-drying, where the movement of the product becomes a key driver of performance, quality and process control, making the process simple and elegant.
From powder to beads: a new generation of freeze-dried forms.
Lyophitech technology transforms liquid formulations into perfectly individualised freeze-dried beads, offering an innovative alternative to freeze-dried cakes and conventional powders.
Thanks to their spherical shape, the beads benefit from a three-dimensional surface area for mass transfer. Sublimation takes place uniformly throughout their entire volume, whilst their constant movement ensures an even distribution of heat and pressure. The result is a highly microporous structure, guaranteeing rapid reconstitution, excellent dissolution quality and optimal preservation of active ingredients.
Beyond their drying performance, these beads open up new possibilities for the pharmaceutical formulations of the future.
Our technology enables the production of monodisperse (uniform diameter) or polydisperse beads, depending on the application’s requirements. Precise control over the diameter and mass of each bead allows for unit-dose dispensing by counting, offering an accurate alternative to traditional powder weighing methods.
This approach facilitates the automated filling of vials, syringes or medical devices whilst minimising issues related to dust, static electricity and powder segregation.
To support this industrial development, Lyophitech is expanding its ecosystem with partners specialising in isolators, aseptic transfer systems, high-precision counting and automated bead packaging, enabling this new dosage form to be integrated into production lines that comply with pharmaceutical requirements.