Dryers part2

Dryers
Static bed dryers- Batch type

a. Tray (and truck) dryers
b. Freeze dryer
a. Tray (and truck) dryers
• Most commonly used in pharmaceutical plant operations
• Tray dryers are also called “Shelf”, “Cabinet”, “Compartment” dryers
 May be direct/ indirect type
 Usually 3-20 trays
• Truck dryer is preferred over tray dryers due to greater ease in loading/ unloading of material
 Usually 1 or 2 tiers of tray with 18 or more trays per tier
• Trays may be solid base/ perforated

• Well insulated cabinet with strategically placed fans and heating coils as integral part of unit
• With adjustable louvers and exhaust system
• Air circulation speed = 200-2000 ft/min
• Source for heating the dry air: Steam/ electricity
Tray Dryer Truck Dryer
• Vacuum shelf can be used in case of:
• Low temperature drying of thermolabiles (penicillin preparation)
• Solvent recovery
• Extremely low residual solvent levels (Ethanol extractives)
b. Freeze dryer
• Freeze-drying is a process of drying in which water is sublimed from the product
after it is frozen. This is also known as sublimation drying.
• As the dried product has great affinity for water (lyophilic – liquid loving)
therefore this process is also known as lyophilization
• In this process the liquid is first frozen to ice before application of vaccum, to
avoid frothing then sublimation of frozen ice is carried out under reduced
pressure.
• Also called cryodessication or gelsiccation
• Used for drugs which:
lose their viability in the liquid state
readily deteriorate if dried in air at normal atmospheric pressures,
these may be heat sensitive or
they may react readily with oxygen,
Material to be dried is first
frozen and then subjected
under a high vaccum to heat
Frozen liquid sublimes, leaving

only solid, dried component of
the original liquid
Dried product is readily

redissolved/ resuspended by
addition of water before use
Principle of freeze drying
• Sublimation is a process in which, on heating, the solid gets converted directly to
vapors without intermediate formation of a liquid state and on condensation, the
vapours get converted back to the solid state.”
• The product obtained is called sublimate.
• It takes place at temperatures and pressure below the triple point of water i.e.
4.579mm Hg, temperature 0.0099 OC
• Sublimation is used to create freeze-dried substances, for example tea, soup
or drugs in a process called lyophilization, which consists of freezing a solution
or suspension and heating it very slowly under medium to high vacuum.
The triple point is the
point possessing a
fixed pressure and
temperature at which
the solid, liquid and
gaseous phases of a
material are able to co-
exist independently.
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Line OA:
In this diagram, line OA shows the melting points of the solid substance at different pressures.
In this line, left side shows the existence of solid form while the right side shows the existence
of liquid form. This line shows the points of co-existence of the solid and the liquid.
Line OB:
The line OB shows the vapor-pressure curve of the liquid at different temperatures. Above this
line liquid phase exists and below this line vapor phase of the substance exists. This line shows
the points of co-existence of the liquid and the vapors.
Line OC:
The line OC shows the sublimation curve of the solid. This line shows the points of co-
existence of the solid and the vapors at different states of temperatures and pressure.
Point O:
In this diagram, the point O represents the triple point.
Stages of freeze drying:
There are 4 stages in freeze drying process:

1. Pre-freezing
2. Vacuum
3. Primary drying (sublimation)
4. Secondary drying
Stages of freeze drying
Prior to freezing, pretreatment i.e. formulation revision is done where different
components are added to increase product’s stability, improve processing or
preserve appearance etc
1. Pre-Freezing: The product is frozen. This provides a necessary condition for
low temperature drying, temperature below or at -20 oC
2. Vacuum: After freezing, the product is placed under vacuum i.e. pressure is
reduced sufficiently
 Rotary pumps/ Ejector pumps
3. Primary Drying: Heat is applied to the frozen product to accelerate
sublimation. (95% water is removed)
4. Secondary Drying: Temperature is raised (upto 50 oC) or dessicants are used
to remove the traces of water left
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Applications of freeze drying:
• Lyophilization (freeze-drying) is often used to prepare dry pharmaceutical

formulations to achieve commercially viable shelf lives.
• Freeze drying is used for the manufacture of certain pharmaceutical and
biological products which are thermolabile. It is also used for drying blood
plasma, vitamins, enzymes, hormones and antibiotics.
• Freeze dried products are more stable than vacuum dried products and often
more readily soluble. (hence, increases the shelf life of some
pharmaceuticals for many years.)
• By removing the water from the material and sealing the material in a vial, the
material can be easily stored, shipped, and later reconstituted to its original form
for injection.
• Since freeze drying is very slow and expensive process it is preferably used for
those products which cannot be dried by any other method.
• Furthermore, it is capable of concentrating substances with low molecular
weights that are too small to be removed by a filtration membrane.
• Lyophilization is the most common technique for the manufacturing of parenteral
pharmaceutical product when the product is unstable in aqueous solution.
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THINK  ……..
1. Freeze drying is also called

sublimation drying…
THINK a little more……..
2. The main principle involved in the

process of freeze drying is freezing under
vacuum….
Static bed dryers- Continuous type
a. Tunnel dryer
b. Drum dryer
a. Tunnel dryer
• Adaptation of truck dryer for continuous drying
• Trucks are moved through a tunnel by a moving chain
• It is more accurately called a semi-continuous process as individual loading
unloading is required
• Conveyer dryers are truly continuous tunnel dryers
b. Drum dryer
• One or two slowly rotating, steam heated cylinders
• Agitated trough containing feed material
• Dip-feed concept, Spray or splash feed may be present
• The dried material is then scrapped by the scraper
• Solution/ suspension feed may be used e.g zinc oxide or kaolin suspension
• Confined to drying of thermolabiles that require short contact time
Moving bed dryers- Batch type
a. Vacuum dryer
b. Pan dryer
a. Vacuum dryer
• Rotating double cone vacuum dryer is the most common shape
of Vacuum tumble dryer
• Operating under vacuum, this dryer provides controlled drying
at low temperatures, with solvent recovery (condenser) and
increased rates of drying
• Rotates at 6-8 rpm
• Reduced drying time of granules; 2-4 hrs
• Not used for waxy material due to formation of aggregates.
• Largely incorporated in granulation designs to permit multiple
processing steps in a single equipment
• Vacuum is supplied by conventional pumps, blowers, steam jets
• Heat is transferred by heated shell and heating fluid/ heat transfer
through vapors (circulating through the jacket)
• Pan dryer are the moving bed vacuum dryers of indirect type

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Dryers part2

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Dryers

Static bed dryers- Batch type

• Trays may be solid base/ perforated

Frozen liquid sublimes, leaving

Dried product is readily

There are 4 stages in freeze drying process:

• Lyophilization (freeze-drying) is often used to prepare dry pharmaceutical

1. Freeze drying is also called

2. The main principle involved in the

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