Lynfinity spray-freeze-drying process features a controlled spray of liquid product into a cryogenically cooled freezing chamber. The resultant frozen particles of the liquid product are freeze-dried in the drying module. The drying chamber contents are both transported and heated to promote rapid sublimation and prevent agglomeration.
The continuous spray-freeze-drying process starts with bulk liquid product and ends with the discharge of dried particles, featuring total containment from formulation to powder filling. This enables higher sterility assurance levels, whereas traditional freeze-drying requires additional external material handling, for example during filling. Upon completion of drying, the uniform, dried spherical product allows for the use of a variety of containers (vials, syringes, inhalation systems etc.).
Continuous Manufacturing in pharmaceutical industry has a great potential in terms of sustainability as the reduced plant footprint leads to space and energy-savings. Lynfinity is a Continuous Manufacturing process developed for freeze drying.
Designed for continuous process from fermentation to final packaging
Greater throughput flexibility: minimization of scale up and scale down challenges
Better quality attributes: improved product uniformity through a gentle drying process
Total containment from formulation to powder filling: higher sterility
assurance level (SAL)
Higher productivity and lower downtime: increased concentration, reduced drying time, no vapour flow limitation, direct heat transfer from shelf minimal product, no product resistance from cake thickness
Reduced running OPEX costs: reduced operating and utilities costs and reduced number of operators
Reduced CAPEX i.e. capital investments: equipment foot print reduction and no loading system requirements
Faster reconstitution time: increased Specific Surface Area (SSA) leading to faster reconstitutions
Continuous operation dictates controlled movement that allows sufficient resident time for drying. However, it is imperative that the transport be gentle on the product.
Lynfinity LAB features a controlled spray of liquid product into a cryogenically cooled freezing chamber. The resultant frozen particles are stored in a cooled canister to transfer for drying in a traditional lab freeze dryer.
The Laboratory Lynfinity can be a useful tool for introduction to spray freeze drying, technology evaluation, and process development, with a low barrier to entry.