In response to the limitations of conventional shelf-type freeze dryers - particularly their reliance on static drying and extended processing times – RHEOFREED has been developed to drive efficiency, both economically and operationally. Shelf dryers, long considered the industry standard, often suffer from slow and uneven drying performance. The idea behind this new development was to revolutionise freeze drying by integrating controlled mixing into the process. By integrating agitation into the freeze-drying process, RHEOFREED delivers a transformative leap in drying efficiency, uniformity, and speed. This breakthrough technology has the potential to redefine pharmaceutical manufacturing - poised to replace conventional shelf dryers and establish a new industry benchmark for performance, reliability, and innovation.
Built on the proven Conical Dryer Blender (CDB) platform, RHEOFREED redefines freeze drying with a compact, efficient, and contamination-free solution. The system is featuring a conical vessel with external suction ports and no internal moving parts. By integrating cold-resistant materials and significantly enlarging vacuum piping - nearly five times the conventional diameter - it achieves deep vacuum conditions essential for freeze drying at -20 to -30°C.
The process begins by cooling the vessel and inserting a freezing nozzle. Once vacuum is achieved, liquid material is pumped in and instantly transformed into frozen powder via spray freezing. The nozzle is then removed, and the vessel rotates during drying to ensure uniformity. After drying, the powder is discharged directly - completing the cycle with minimal handling.
Five game-changing features
Spray freezing without trays
The system employs a spray-freezing technique powered by an ultrasonic nozzle, enabling precise and efficient continuous transformation of liquid into frozen powder without the need for external freezing agents. As a result, it reduces both the physical footprint of the equipment and the time required for the freezing stage.
Faster drying time
Tests show significant time savings:
- Linear peptides: 100 hours → 20 hours (80% reduction)
- Cyclic peptides: 200+ hours → 56 hours (75% reduction)
Superior product quality
RHEOFREED ensures:
- Uniform moisture content through continuous mixing
- Lower residual solvents (e.g., acetonitrile: 1500 ppm → 162 ppm)
- Preserved molecular integrity
Direct powder output
The system produces dry powder directly, eliminating the need for post-drying milling.
Shortened overall process
Preparation, drying, removal, and cleaning are streamlined:
- No trays to load or wash
- Direct discharge via bottom valve
- Simple vessel design for easy cleaning
Tailored for both small-scale testing and full-scale production, RHEOFREED is GMP-compliant with capacities ranging from 0.1 to 100 litres. A compact 100 mL model is available for pharmaceutical clients working with limited sample volumes. This groundbreaking system will be showcased at CPHI Frankfurt 2025, offering attendees an exclusive first-hand look at the future of freeze drying.
Dec Group (Hall 9.0, stand A10)