Your application Safe freezing of bulk drug substances (BDS)

The stable and reproducible storage of bulk drug substances, or BDS for short, is a key component of modern biopharmaceutical manufacturing processes. Especially for sensitive active ingredients such as monoclonal antibodies, enzymes or vaccines, the freezing process is crucial for maintaining the quality of the active ingredient for weeks or even months. Refolution offers scalable and validatable solutions that reliably support the safe freezing, storage and transport of these substances - from process development to routine production.

When freezing BDS, it is not just a matter of bringing the substance to a target temperature. Rather, factors such as the freezing speed, uniform temperature distribution within the container and the control of supercooling and physical stress directly influence the stability and effectiveness of the product. Even slight fluctuations in the temperature profile can lead to structural changes in the molecule and thus have a lasting effect on product quality. A reproducible and validated freezing process is therefore essential - not only for product safety, but also for regulatory requirements and economic efficiency.

Refolution provides advanced freezing systems that enable fast and uniform freezing while ensuring complete control over the critical process parameters. The systems have a modular structure and are designed for both smaller volumes and large batches of up to 75 litres per unit. Thanks to integrated temperature recording and digital process monitoring, all freezing processes can be fully documented and validated. The compact design also allows seamless integration into existing laboratory or production environments, even under GMP conditions.

Our solutions are used in a variety of application areas. These include the production of monoclonal antibodies, the production and storage of vaccines, the processing of recombinant enzymes and use by contract manufacturers with changing requirements. In long-term storage and temperature-controlled transport, precise freezing also plays a decisive role in quality assurance over the entire life cycle of the product.

The targeted use of validated freezing technology protects BDS from degradation, denaturation or unwanted aggregation. At the same time, reproducibility across different batches is significantly increased, which benefits both regulatory requirements and internal quality standards. Our systems are fully compatible with common container solutions such as the Celsius® series of FFT bags with Safecore™ technology and can be customised to meet the specific requirements of your process on request.

If you would like to optimise your BDS processes, we will be happy to support you with our expertise. From the selection of suitable vessels and the design of the freezing profile to the selection of the right shipper, we will guide you through all phases of process development. Our experts will be happy to advise you - personally, application-orientated and with many years of experience in biopharmaceutical practice.

Contact us and find out more about our solutions for the safe freezing of bulk drug substances.

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Cornelia Schröder
Cornelia Schröder
Assistant to the management