Consortium aims to ensure freeze-drying tech not left in the cold

LyoHUB​ wants to increase the competitiveness of manufacturers using such techniques, which are used in the food and pharmaceutical industries.

Lyophilization is the process by which water is gently removed from materials to make them more stable and lengthen their shelf life.

It requires big pieces of equipment that create a low temperature and pressure environment to push water into the vapor phase, so it leaves the material and collects on condenser coils.

Technology roadmap​

The consortium is developing a technology roadmap, expected to take around 18 months, for lyophilization to prioritize research and development projects and goals, said Elizabeth Topp, head of Purdue’s Department of Industrial and Physical Pharmacy who co-leads the center.

“The roadmap project will project 10 years to what the technology looks like in the future and work our way backwards to see what we have to do now to reach that state,” ​she said.

“It will look at pre-competitive research projects and education to improve the process.​

“You don’t think of it when enjoying the dried strawberries in your morning cereal, but lyophilization is a $30bn piece of the US food and pharmaceutical manufacturing industry.”​

However, the current process hasn’t changed in 50 years, is very expensive and this stagnation could have a negative economic impact, as companies look to offshore manufacturing to reduce costs, said Topp who is also the Dane O. Kildsig Chair in Industrial and Physical Pharmacy.

“Consortium members from industry will frame the problems they face, and members from the academic and research side will help work on solutions, while regulators are kept in the loop to ensure the safety and standards so that changes can be quickly approved​,” she said.

“We can apply what we learn to make other manufacturing processes better, faster and more efficient. This will mean safer and more affordable products.”​

The consortium will bring together industry and academia, the Food and Drug Administration and other government agencies, equipment manufacturers, and end product users – current partners include Pfizer, Millrock Technology and Janssen.

It will have input on the roadmap at the annual meeting of the International Society of Lyophilization Freeze Drying (ISLFD​) in Chicago.

From the end of October a pilot scale facility will be available, said Topp.

“The demo center will be available to consortium members, from pilot and lab scale, so if people have an interesting idea there will be equipment manufacturers to end users who will have a place to show their machines, for us to do research and industry to connect and have an entry point to learn more about Lyophilization.”​

Topp said since the equipment is sealed and due to the time it takes if something goes wrong with processing time is lost.

“Lyophilization is not efficient from an energy efficiency or time perspective, it can take days or weeks to run a cycle, if we can make improvements in the existing process we can open the door to new freeze drying technology.​

“We have an assortment of people at Purdue, we have a strong engineering school on campus, an interest in manufacturing, a food science program and college of pharmacy so it gives us strength in all areas.” ​

Conditions similar to outer space​

Alina Alexeenko, an associate professor of aeronautics and astronautics, said the conditions required for lyophilization are similar to those in outer space.

“Inside the lyophilizer the conditions are a rough vacuum, similar to that at 50 to 100 kilometers altitude in the Earth’s atmosphere, and the fluid dynamics, heat transfer and certain molecular effects are different from what we see under normal conditions​,” she said.

“We need to approach the equipment design the same way we approach a new spacecraft design, by first understanding in detail all of the forces and mechanics involved and using some of the special physical effects of the rarefied environment to our advantage.”​

Alexeenko said the technology is used for baby food, infant formula to preserve more sensitive components such as pre and probiotics and yogurt for toddlers.

The Commerce Department’s National Institute of Standards and Technology (NIST) selected Advanced Lyophilization Technology Consortium LyoHUB as one of 16 awards to help accelerate growth of manufacturing in the US from its Advanced Manufacturing Technology (AMTech) program.   

A LyoHUB technology roadmapping workshop will be held October 6 - 7 at Purdue University.