GEA Strengthens Pharma Portfolio With New Freeze Drying Technology Center

GEA introduces the RAY Plus series to optimize energy consumption and throughput in large-scale food and pharmaceutical processing through advanced fluid dynamic modeling. The RAY Plus series is a batch-based lyophilization solution designed to provide a 30% increase in production capacity compared to standard industrial units of an equivalent footprint. Utilizing proprietary Computational Fluid Dynamic (CFD) modeling, the system achieves a 50% reduction in internal pressure drop, making it highly relevant for the sustainable production of coffee, fruits, and bioactive ingredients.

Optimization of Vacuum Dynamics and Throughput
The core technical advancement of the RAY Plus lies in its redesigned cabinet geometry, which was developed using a proprietary CFD model to evaluate flow and pressure losses under deep vacuum conditions. By installing vapor traps on both sides of the cabinet and allowing vapor entry from both the top and bottom, the system facilitates a nearly 50% reduction in pressure drop. This mechanical optimization allows the equipment to operate at lower vacuum levels—often below 0.15 mbar—while maintaining high sublimation rates exceeding 3 kg/m²h.

In practical application, these advancements mean that the RAY Plus can achieve the same daily output as legacy systems while utilizing approximately 20% less energy. The integration of four condensers—three in operation and one in de-icing—starting from the RAY 125 Plus model, allows for a larger condensing surface and enables operation at condenser temperatures approximately 6 °C warmer than traditional configurations.

Integration within the Digital Supply Chain
To meet the requirements of the modern automotive data ecosystem and industrial IoT standards, the RAY Plus features an intuitive user interface on the unit front that supports secure remote access and centralized control. Up to six cabinets can be networked to share a common control and support system, ensuring even load distribution across the production floor. This modularity allows for scalable growth, with cabinet sizes ranging from 45 m² to 180 m² and heating plates configured in layers of 10, 15, or 20.

The system’s hygiene standards are maintained through a circular, self-draining cabinet design. All washdown water is directed to specific drain points at the bottom, and residual moisture is removed by applying a brief vacuum. This reduces downtime between batches and ensures compliance with global sanitary standards for sensitive products like probiotics and enzymes.

Technical Performance and Benchmarking
When compared to mechanical refrigeration systems, which often face high operational costs, the RAY Plus provides a balanced alternative by leveraging its increased capacity-to-footprint ratio. While traditional batch dryers may struggle with hotspots or uneven drying, the RAY Plus ensures uniform heat transfer across all tray layers. Furthermore, the system is compatible with existing infrastructure, allowing it to be connected to the latest industrial heat pump technologies to further decarbonize the production cycle.

www.gea.com