Freeze-drying technology
What is Freeze-Drying (Lyophilization) and How Does the Process Work ?
Freeze-drying (lyophilization) is an advanced dehydration technology that removes moisture from products in a vacuum environment through direct ice-to-vapour sublimation — bypassing the liquid phase entirely. The method is widely used in food processing, pharmaceutical manufacturing, biotechnology and agribusiness.
The lyophilization process consists of several key stages: deep-freezing of the product at temperatures down to -30°C…-50°C, chamber vacuum creation, and controlled moisture removal through primary and secondary drying phases. Stable process operation requires deep-freeze refrigeration systems, vacuum pumps and automated process parameter control — fully compliant with EU GMP Annex 1 and food safety standards.
We engineer and deliver industrial freeze-drying equipment and lyophilizers using energy-efficient solutions including CO₂ (R744) refrigeration systems — ensuring stable cold supply, reduced energy consumption and full compliance with EU F-Gas Regulation 2024/573 and environmental standards.
How it works
The freeze-drying process:
Freezing
Deep-freezing of products to -30…-50°C
Vacuum
Creating a vacuum and the transition of ice to vapor
Freeze-dried product
Removes up to 90% of moisture without compromising texture or nutritional value
What's the benefit ?
Advantages of sublimation:
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Preserved Product Structure, Flavour and Nutritional Value
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Extended Shelf Life Without Preservatives
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Minimal Loss of Bioactive Compounds and Nutrients
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Product Weight Reduction of Up to 90%
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High ROI at Industrial Production Scale
Where it is used
Industrial Applications of Freeze-Drying & Lyophilization
Freeze-drying (lyophilization) is widely used across food processing, pharmaceutical manufacturing, biotechnology and agribusiness industries. The technology preserves product structure, aroma, nutritional value and bioactive compounds without exposure to high temperatures or chemical preservatives — maintaining premium product quality throughout the entire shelf life.
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Freeze-Dried Berries & Fruits
Freeze-drying of berries and fruits preserves up to 95% of vitamins, natural flavour and aroma. Lyophilized strawberries, raspberries, blueberries, apples and mango achieve extended shelf life without preservatives — maintaining premium clean-label quality. Industrial freeze-drying equipment for berries and fruits is widely used in healthy snack production, confectionery and functional food manufacturing across EU markets.
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Freeze-Dried Meat & Fish
Lyophilization of meat and fish preserves protein structure, nutritional value and microbiological safety of the final product. Freeze-drying technology is widely used for production of military rations, expedition and outdoor food, ready meal ingredients and premium pet food — with extended shelf life of up to 25 years without refrigeration. Industrial lyophilization chambers ensure consistent product quality and full compliance with EU food safety and hygiene regulations.
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Medicinal herbs and botanical ingredients
Freeze-drying of medicinal plants and herbs preserves essential oils, active phytochemicals and pharmacological properties — with significantly lower degradation compared to conventional drying methods. Lyophilization is widely used in the production of phytopharmaceuticals, botanical extracts, nutraceuticals and dietary supplements (food supplements) — fully compliant with EU Directive 2002/46/EC on food supplements and GMP manufacturing standards.
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Pharmaceutical products
In the pharmaceutical industry, lyophilization is used for the production of vaccines, biologics, injectable drug formulations and active pharmaceutical ingredients (API). Freeze-drying technology ensures long-term stability of active compounds and extended shelf life without refrigeration — critical for global cold chain distribution. Our industrial lyophilization equipment fully complies with EU GMP Annex 1, EMA guidelines and international quality standards ISO 13408 for aseptic processing.
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Freeze-Dried Vegetables
Freeze-drying of vegetables preserves natural colour, texture and flavour profile — with minimal nutrient loss compared to conventional drying or canning methods. Lyophilized vegetables are widely used in the production of instant soups, sauces, ready meals and clean-label food ingredients for retail and food service markets across Europe. Industrial freeze-drying equipment ensures uniform moisture removal and precise humidity control — meeting EU food manufacturing quality and safety standards.
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Pet and farm animal feed
Lyophilization of pet food and animal feed preserves proteins, fats and essential nutrients without artificial additives or preservatives — maintaining natural palatability and nutritional integrity. Freeze-drying is widely used for production of premium pet food, raw diet (BARF) products and natural treats for dogs, cats and exotic animals. Industrial freeze-drying systems ensure consistent product quality, extended shelf life and full compliance with EU animal feed regulations (EC) No 767/2009.
The freeze-drying equipment we are implementing
Technical specifications
Key Specifications of Industrial Freeze-Drying Equipment
Industrial lyophilization (freeze-drying) systems are engineered to meet specific productivity targets, cycle duration, temperature regimes and seamless production line integration requirements. Below are the baseline technical specifications of our freeze-drying equipment.
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Freeze-Drying Cycle Duration
From 18 to 48 hours depending on product type, layer thickness and target moisture content. Process optimisation reduces lyophilization cycle time without compromising product quality.
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Equipment Productivity & Capacity
From 50 to 1000 kg per cycle depending on lyophilization chamber configuration. Scalable freeze-drying capacity tailored to your production volume requirements.
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Temperature Regimes & Process Control
Deep-freeze capability down to -40°C with stable vacuum environment operation. Precise shelf temperature control at every stage of the primary and secondary freeze-drying process.
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Working Vacuum & Pressure Control
Operating pressure within 0.05–1 mbar ensures efficient direct ice-to-vapour sublimation — bypassing the liquid phase for optimal freeze-drying quality and process stability.
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Production Line Integration
Lyophilization equipment integrates seamlessly into existing production processes, automation and monitoring systems — with full PLC-based control and remote SCADA access.
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Commissioning, Staff Training & After-Sales Service
Full freeze-dryer startup cycle: installation, vacuum testing, temperature calibration and operator training. We provide warranty and post-warranty service, technical support and remote equipment monitoring.
Let's compare
Comparison: freeze-drying vs. conventional drying
| Parameter | Freeze-drying | Traditional drying |
|---|---|---|
|
Process temperature |
-30…-50°C |
+50…+90°C |
|
Preservation of structure |
Up to 95% |
40–60% |
|
Preserving vitamins |
Maximum |
Partial loss |
|
Shelf life |
Long-lasting and preservative-free |
Limited |
|
Product quality |
Premium |
Medium |
Conclusion: freeze-drying (lyophilization) delivers maximum preservation of product structure, nutritional value and organoleptic properties. The low-temperature sublimation process removes moisture without damaging cellular structure — retaining up to 95% of bioactive compounds and nutrients.
Long-term, freeze-drying technology offers significant ROI for manufacturers targeting premium market segments, export markets, functional food production and extended shelf life without artificial preservatives — fully aligned with EU clean-label and sustainability trends.
Ready to implement freeze-drying technology in your production facility?
Consultation
FAQ
Frequently Asked Questions About Freeze-Drying & Lyophilization
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Freeze-drying (lyophilization) is an advanced dehydration technology that removes moisture from products in a high-vacuum environment at low temperatures. Water transitions directly from ice to vapour through sublimation — bypassing the liquid phase entirely.
This low-temperature process preserves product structure, bioactive compounds, nutritional value and organoleptic properties — making freeze-drying the preferred technology for pharmaceutical manufacturing, functional food production and nutraceutical processing across EU markets.
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Unlike conventional drying at high temperatures (+60…+90°C), freeze-drying occurs at deep-freeze conditions (-30…-50°C) in a high-vacuum environment — eliminating heat-induced product degradation.
This allows manufacturers to:
- Preserve natural colour and appearance
- Retain vitamins, minerals and bioactive compounds
- Maintain original cellular structure and texture
This is why freeze-dried products achieve premium clean-label quality and command higher market value across EU food and pharmaceutical sectors.
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Industrial lyophilization requires specialised freeze-drying equipment consisting of:
- High-vacuum chamber
- Deep-freeze refrigeration system
- Vapour condenser unit
- Automated PLC-based process control system
We deliver industrial freeze-drying systems on a full turnkey basis — with complete process automation, SCADA integration and GMP-compliant documentation.
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Freeze-drying technology is widely used for:
- Berries and fruits
- Vegetables and herbs
- Meat, poultry and fish
- Medicinal plants and botanical extracts
- Pharmaceutical products, vaccines and biologics
- Premium pet food and animal feed ingredients
Lyophilization allows manufacturers to achieve extended shelf life of up to 25 years without artificial preservatives — meeting EU clean-label and food safety standards.
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When hermetically sealed, freeze-dried products achieve a shelf life of 1 to 25 years without quality loss — depending on product type, packaging material and storage conditions.
The near-complete elimination of moisture content significantly reduces microbial growth risk — ensuring microbiologically stable, safe and HACCP-compliant product throughout its entire shelf life.
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Yes, we deliver a complete turnkey freeze-drying production launch cycle including:
- Technical engineering and process design
- Freeze-dryer and lyophilization equipment selection
- Installation and commissioning
- Operator training and staff qualification
- Warranty and post-warranty service support
We serve clients across Ukraine and Eastern Europe — with full remote project management and on-site commissioning available.
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Freeze-drying requires higher energy input compared to conventional drying methods — however it produces premium high-value-added products that command significantly higher market prices across EU food and pharmaceutical sectors.
Modern vacuum systems and heat recovery solutions allow significant optimisation of energy consumption and reduction of operational costs — fully aligned with EU Energy Efficiency Directive and Green Deal sustainability targets.
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Testimonial
Customers Says
Koriell Group completed the development of a refrigeration machine and its installation on CO2 for berry sublimation. We are very pleased with the cooperation because the work was completed on time. The equipment operates productively and energy-efficiently, which in turn reduces the cost of finished products.
We have had a positive experience working with the Coriel Group team. Just recently, 20-year-old blast freezing system with a new, modern and more efficient system that works flawlessly.
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