Lyophilization Positioning System (LPS)
Our patent-pending Lyophilization Positioning System (LPS) correlates temperature and pressure data onto the phase diagram of water, which serves as a map. The LPS tracks the real-time position of the product through various phases and key milestones, making the data meaningful as it transitions through the lyophilization (freeze-drying) process. The interface is customizable and can optionally display both historical and destination paths, providing a clear visualization of the intended process trajectory.
How the LPS Guides Your Product
The freeze-drying process starts with your product in the "LIQUID" region, where it contains water at room temperature. As the compressor cools the product, it moves leftward on the phase diagram, crossing the freezing point into the "ICE" region.
Once frozen, the vacuum pump lowers the pressure, causing a vertical descent on the diagram to the sublimation line. To optimize sublimation and avoid damaging the product or vacuum pump, pressure is further reduced, following a vacuum assisted cooling path along the sublimation line to a target set point (e.g., 500 mTorr).
At this set point, heaters raise the temperature, pushing the product into the "VAPOR" region where ice sublimates efficiently. This stage, called primary drying , is where most of the ice is removed, typically over hours or days, to maintain product quality.
As sublimation nears completion, secondary drying begins, where the temperature increases to the final drying temperature. In the final drying stage, final drying temperature holds steady while the pressure is reduced to remove residual moisture.
Persistent Dial
The LPS interface includes a persistent dial that provides real-time monitoring of key process indicators. It displays live data such as pressure, shelf temperature, and trap temperature, along with the current phase state of the product. The dial also tracks heater power settings and provides an estimate of the amount of water removed during the process. Additional key metrics include the pressure set point, elapsed time, and cumulative power consumption. Continuously presenting this information, enables precise process management and real-time decision-making.
Customizable Controls
The LPS interface features editable controls for a set point pressure, a final temperature target, vacuum pump enable temperature, and PID settings. Adjustments to the PID (Proportional-Integral-Derivative) algorithm enables fine-tuning for a second-order response to optimize system performance.
Transient Plots: Temperature, Pressure, Mass Removed, and Power
The LPS interface offers a comprehensive set of transient plots that track real-time changes in temperature, pressure, and estimated mass removed from the product, along with key power metrics. In addition to pressure vs. time and temperature vs. time, power-related plots display Energy (kWhr), Power (W), RMS-Voltage (V), and RMS-Current (A) over time, giving a full picture of system efficiency.
These dynamic plots provide valuable insights into how energy and power usage are managed during the freeze-drying process, allowing for optimized performance and operational cost control. With these visual tools, monitoring the entire process is straightforward, ensuring product quality and resource efficiency every step of the way.
Functional Controls and Sensor Mapping
The LPS interface features intuitive functional controls, with checkboxes for enabling or disabling relays, and drop-down menus for enable settings and customizing sensor and relay mapping. The relay mapping allows sensors to be bypassed or rerouted to different input ports, providing flexible configuration options. One of the settings incorporates a patent-pending feature that enables circuitry to disable power to the pressure sensor when not in use, helping to extend sensor lifespan. These controls enhance system adaptability and longevity, ensuring efficient and reliable operation throughout the lyophilization process.