Refolution of freeze drying

Low-temperature central cooling systems from -40 °C to -110 °C for demanding processes such as freeze-drying.

Introduction of central cooling system

The centralised refrigeration system is essentially a stratified storage system with a heat transfer medium that can store, charge and provide different temperature levels in the different layers.This means that in low-power process steps, the power can be stored in the form of cold heat transfer media and called up directly in power-intensive process steps. This enables a high specific cooling capacity with significantly fewer chillers and a reduction in power peaks in the electricity and cold water network, particularly in batch processes such as freeze-drying. Thanks to a patented internal design, the storage tank is able to charge and discharge different layers simultaneously without them mixing. The stratified storage tank is optimally charged for temperatures below -40 °C with the cold air chillers from Mirai Intex, using only air as the refrigerant.

Planning, consulting and realisation

The central refrigeration system is optimised precisely to the customer's requirements and the process. The load profiles of the consumers, such as the recipes of the freeze-drying process, are analysed and compared with the simultaneity of production. For example, with four freeze dryers (GT) in parallel operation with a filling line with 25 % redundancy, this can mean that in the past 4 * 125 % = 500 % refrigeration capacity was installed whereby only 1/3 of the capacity is usually required for freezing (100 %) during drying. This usually results in the worst load case of 1 GT for freezing (100 %) and 2 GTs for drying (2*33 %) a load requirement of 166 %. With a high level of redundancy, 250 % can then be installed, which is half the capacity of conventional chillers. The concept is therefore also suitable for retrofitting existing systems.

Central cooling system from the front
Central cooling system from the front
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Technical details of the central cooling system

  • Memory design

    Thanks to the patented design of the storage tank, several chillers can charge the storage tank and generate different temperature levels. This means that the chillers are always operated at the optimum operating point.

  • Different temperature levels

    As on the cooling side of the storage tank, several consumers can be connected to the storage tank. Thanks to the different temperature levels, the consumers can be supplied with cold at different temperature levels simultaneously as required.

  • Stratified storage

    The stratified storage tank separates the cooling generators from the consumption side and initially serves as a hydraulic separator. It also has several zones that can be used to supply different consumers at different temperatures at the same time. Large outputs can be developed at short notice via storage layers. This reduces the output of the chillers to be installed and peaks in the electricity and cold water network.

Reliable, durable, efficient and safe for people and the environment  
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Technical versions

  • Refrigeration technology

    For temperatures below -40 °C, the tried-and-tested cold air chiller from Mirai Intex is used. It is characterised by high efficiency and reliability in this area. Thanks to the refrigerant air (R729) the system is environmentally friendly and there are no restrictions or regulations imposed by the EU F-Gas Regulation and REACH.

Your advantages at a glance

Future-proof
Future-proof

Air as a refrigerant is free of charge, free of regulations and safe. The systems are robust and specially designed for low temperatures.

High reliability
High reliability

Proven technology - Made in Germany. Low-wear and redundant.

Flexible
Flexible

Customised design with freely selectable temperatures in operation with high power density.

Efficient
Efficient

Speed-controlled, energy storage with reduced load peaks in the electricity and cooling water network

Safe for people and the environment
Safe for people and the environment

Natural refrigerant without high pressures, low training requirements

Low maintenance & durable
Low maintenance & durable

No leak test, air-bearing compressor = no wear, no oil. High-quality system technology.

Christian Berger

CSL Behring

Christian Berger · Global Director - Process and Technology Owner for Aseptic & Sterility

Refolution supported me in the technical verification of design and dimensioning of a Natural Refrigerant Cooling System for a new Freeze Dryer system.
I was very happy with the immediate support and competence of the Refolution Team. Thanks for your help.
Oliver Fleischer

HOF Sonderanlagenbau GmbH

Oliver Fleischer · Head of Service / Head of development - refrigeration technology department

With Refolution, the future of sustainability succeeds, coupled with efficiency and foresight.
The professional for the future.

Technical details & options

Technical information

Options

    • Air as refrigerant with GWP = 0
    • Variable base plate area from 10-40 m2
    • Oil as carrier medium
    • Nearly no requirements for machine room installation
    • Experience since 2007
    • Modular design
    • "Scale up" via central cooling

Our suitable services for your freeze drying

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