New Vacuum Nucleation Induction Method for Lab Freeze-drying Processes

Lyonuc is a new nucleation induction method developed by Telstar that facilitates scaling up and optimisation from a laboratory pilot scale to industrial scale. It is a solution for effectively inducing the start of nucleation in the freeze-drying process that enables research centres and pharmaceutical laboratories to run freeze-drying process more efficiently, increasing the productively and improving the batch uniformly.

Particularly effective when testing and developing new recipes, Lyonuc is a standard option for LyoBeta, the range of twin-vessel pilot-scale freeze dryers designed by Telstar for research, development and scale-up of recipes for pharmaceutical freeze-drying processes.

The LyoBeta range is characterised by attributes of flexibility, high performance, and small footprint required in a laboratory unit, including advanced process control systems, management software and interface features.

Vacuum nucleation induction method

This new nucleation induction method developed by Telstar reduces the duration of the primary drying cycle. The vacuum-induced nucleation produces a change in the solid structure of the solution and manages to homogenise the moment when the freezing starts so that all the vials nucleate at the same time in a few seconds, instead of taking 30-45 minutes which is how long the spontaneous nucleation process typically takes. This method based on controlling the temperature and pressure and inducing the start of the freezing phase, also ensures the uniformity and homogenisation of the vials in all the batches, respecting the product’s physiochemical properties.

The nucleation induction method can be adapted to any type and model of freeze-dryer. Unlike other methods where it is necessary to add gases external to the process or use decompression processes requiring special equipment, this new method only requires controlling the temperature, vacuum, and time. This new method is particularly focused on long duration freeze-drying cycles, where the benefit of reducing the drying time is much greater.

Learn more about controlled nucleation: case study

Learn more about Telstar Research & Medical Portfolio: access to the video

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