1. Thermodynamic Modeling for Real-Time Water Estimation

Our system utilizes advanced thermodynamics to estimate the amount of water present in the product before the sublimation process begins, providing a baseline for the total water that can be extracted. Throughout the freeze-drying cycle, real-time temperature, pressure, power sensor data, and heater settings are continuously analyzed to estimate the sublimation rate and the amount of water being extracted. This feature enables precise monitoring and optimization of the process, ensuring efficient water removal during the freeze-drying cycle.

2. Load Cells for Real-Time Weight Measurement

Some upgrades are equiped with highly accurate load cells to enable direct real-time measurement of the product's weight or accumulated water mass. Unlike other water mass measure techniques, this approach tracks water mass changes by precisely measuring the difference between the product's initial and current weight, offering the most precise way to monitor water extraction. Load cells can be placed on the shelves or the trap for optimal data collection, providing unparalleled accuracy in ensuring optimal freeze-drying conditions.

3. Imaging Sensors for Water Detection

Our advanced smart monitoring system features imaging sensors that assess the product in real-time, offering a precise visual analysis of water content throughout the freeze-drying process. The system operates in two key ways:

1. Image-based decision-making: The sensors detect water accumulating on the trap to estimate water mass and determine moisture levels remaining in the product during final drying. This eliminates the need for manual checks, such as removing trays to feel for residual moisture.
2. NIR (Near-Infrared) analysis: The system calibrates images to measure water content with high accuracy based on specific calibration parameters.

This combination provides a comprehensive understanding of water extraction, complementing thermodynamic and weight-based measurements.

4. Power and Energy Consumption Monitoring

Our smart monitoring system tracks real-time power usage (W) and energy consumption (kWhrs) throughout the freeze-drying process. It concurrently displays both real-time and historical data, correlating this information with other aspects of the process. This enables a detailed analysis of power draw and energy costs associated with each cycle. This capability provides insights into energy usage patterns and helps optimize power consumption for enhanced cost efficiency.