In the pharmaceutical field, it is of utmost importance to sustain the integrity, potency, and shelf life of products such as vaccines, biologics, and oral medicines. Different methods of preservation are often used to attain these objectives, freeze drying being one of the most effective for sensitive products. There are also other methods like refrigeration, canning, and the use of chemical preservatives, which may also be viable options according to the product and production requirements.
In this guide, we will examine the distinctions between freeze-drying and other preservation methods, covering which one is more appropriate for a given situation. We will also cover how pill capsule makers and freeze dry companies aid in choosing the proper method.
What Is Freezing Drying and How Does It Work?
Freeze-dried, otherwise termed “lyophilization”, is a process that entails first freezing the product and proceeding to remove moisture from the product in the subsequent stages. water is frozen and then the environmental pressure is lowered, which turns the water into vapor. This procedure keeps the chemicals or biological composition intact. It is most helpful in preserving biologics, vaccines, proteins, and other sensitive substances that may be destroyed by high temperatures.
The processes include: freezing, primary drying (sublimation), and secondary drying (desorption). In the first stage, a freezer is used to solidify the product, which causes its water content to freeze. After the freezing stage, a vacuum is applied to remove most of the moisture. During the primary drying phase, water undergoes sublimation which changes its state from a solid to vapor.
Lastly, drying in the secondary stage absorbs all remaining moisture within the product, allowing for its long-term storage. Freezing and removing moisture is especially crucial for certain products like vaccines and biologics. Since the active ingredients are extremely sensitive to heat, being freeze-dried helps maintain their effectiveness over time. Moreover, once the products are frozen, they may be kept at room temperature, making them easy to store and transport.
Freeze Drying vs. Refrigeration
Commonly used within pharmaceuticals, a more traditional form of preservation is Refrigeration, which deals with products that need to be stored under low temperatures. Chemical reactions or microbial growth are slowed down, but the moisture is also not eliminated, meaning refrigeration isn’t appropriate for all products. In instances where there is an extreme amount of moisture or a need for long-term stability, refrigeration does not suffice.
As noted above, freeze drying differs from other methods in that it removes moisture completely. This allows the product to be stored at room temperature with more stability. It is even more useful in the case of biologics or vaccines which are temperature-sensitive. In such cases, freezing drying is a better alternative than refrigeration in the long term. There can be a lot of restrictions on the shelf life of refrigerated goods especially if they get exposed to mistreatment during transportation or storage. Whereas with freeze drying, products remain stable and potent even in less controlled environments.
Capsule makers prefer active ingredients in a freeze-dried format, as they can be stored at higher temperatures without having to worry about the product being degraded or damaged. This helps in simplifying the supply chain and improves the shelf life of capsules.
Freeze drying is particularly useful for medications and capsules that need to be shipped all over the world and stored under a wide range of environmental conditions. Avoiding refrigerated environments also helps manufacturers mitigate the risk of temperature damage to the product. For pharmaceutical products that require stability for long periods, freeze-drying promotes efficiency for storage and reduces obstacles to transporting.
Freeze Drying vs. Chemical Preservatives
Many chemical preservatives that are used to inhibit the growth of bacteria, fungi, and any other microorganisms are used in the pharmaceutical industry. However, chemical preservatives can cause a range of issues such as safety and potential consequences of long-term health issues. In the case of patients, the presence of these chemical preservatives can adversely affect them through allergic reactions.
Unlike other processes, freeze drying eliminates the use of products such as chemicals that could potentially modify the composition of any given product. The objective of this process is moisture removal, and by doing so helps preserve sensitive pharmaceuticals without disturbing the product’s composition or introducing dangerous substances.
This makes freeze-drying a more effective method for the preservation of precise pharmaceutical products, especially those that are sensitive to external factors. Moreover, the removal of preservatives helps enhance the purity of the product which lowers the chances of contamination from other foreign additives.
About the manufacturers of pill capsules, the use of freeze-dried components helps eliminate the need for chemical preservatives, thereby making the capsules free from additives and other potentially harmful ingredients.
This advancement in technology makes freeze-dried pills more appealing for patients who wish to minimize the supplementation of additives into their bodies. In addition, the application of such technology provides the guarantee that the products will sustain their biological and chemical properties, hence, giving greater comfort to both the manufacturers and consumers regarding product safety.
Contribution of Freeze Dry Firms
Firms providing equipment for the freeze-drying process plus putting in the required know-how for its execution are referred to as freeze-drying companies. These firms contribute significantly in the area of pharmaceutical manufacturing by providing freeze dryers which are intended to capture high-value pharmaceutical products and protect them from degradation, spoilage, or chemical alteration.
Other services which include, but are not limited to, the installation, servicing, and maintenance of the equipment, as well as the setting of working procedures to ensure that the pharmaceutical companies get maximum benefits from the equipment are also offered.
Pill capsule manufacturers collaborate with companies that specialize in freeze-drying to incorporate freeze-dried components into the capsules. Their partnership not only guarantees that the ingredients remain stable and effective over the shelf life of the capsules but assures efficacy at any time. Furthermore, freeze-drying technology differs in adaptiveness for other product types like injectables, biologics, and oral medicines, thereby allowing manufacturers the adaptability to many different types of products that need preservation.
These companies also provide pharmaceutical manufacturers with customized solutions for both low-volume and high-volume industrial production. Their experience with freeze-drying assures pharmaceutical manufacturers that the products are well preserved without losing potency and quality during storage and transport.
Final Thoughts
Selecting the appropriate preservation technique for pharmaceutical products is crucial for guaranteeing their effectiveness, safety, and longevity. Freeze drying is one of the most effective means of preserving sensitive products like vaccines, biologics, and proteins, proving to be better than refrigeration, canning, and chemical preservatives. For pill capsule manufacturers, freeze-drying is an efficient method for preserving active ingredients cost-effectively and safely.
Cooperating with freeze-drying companies offers pharmaceutical manufacturers access to the latest freeze-drying technology and expertise. In the face of increasing needs for life-saving medications and biologics, the adoption of freeze-dryer technology will be imperative to the quality, safety, and effectiveness of pharmaceutical products around the world.
