The Science of Freeze-Drying
Lyophilization preserves fruit by converting frozen water directly into vapor through sublimation - bypassing the liquid phase entirely. Our three-stage process retains 97% of nutrients, natural color, and flavor while achieving a shelf life of 25+ years.
How Sublimation Works
Below 6.1 mbar pressure, ice transitions directly into vapor without becoming liquid. By maintaining deep vacuum and precisely controlled temperatures, we preserve the cellular structure, nutrients, and flavor of the original fruit.
Below this threshold, ice sublimates directly to vapor
Latent heat supplied through temperature-controlled shelves
Maintained throughout primary drying to drive sublimation
Three-Stage Process
Each stage is precisely controlled to maximize nutrient retention and product quality
Pre-Freezing
Fruits are blast-frozen to -40C at a controlled cooling rate. Rapid freezing creates fine ice crystals that preserve cellular structure. Controlled nucleation ensures uniform freezing across the entire batch.
Primary Drying (Sublimation)
Chamber pressure drops below 6.1 mbar and shelves gently heat the product to drive sublimation. Ice converts directly to vapor, captured by a condenser at -50C to -80C. This removes approximately 95% of moisture while maintaining original shape and volume.
Secondary Drying (Desorption)
Shelf temperature rises to +20C to +40C to break molecular bonds between residual water and the product matrix. Drying continues until moisture reaches 1-3%, ensuring maximum stability for long-term storage.
Industrial System
Our lyophilization facility is built around precision-engineered components designed for food-grade processing at scale.
Vacuum Chamber
S/S316L stainless steel vessel with mirror-polished interior (Ra < 0.4 um). Engineered for full vacuum integrity with a leak rate below 1x10-3 mbar L/s.
Refrigeration Shelves
Temperature-controlled shelves with internal fluid channels ensure uniformity within +/-1.5C across the entire surface. Silicone heat transfer fluid operates from -100C to +200C.
Ice Condenser
Captures sublimated water vapor at -50C to -80C through desublimation. Sized to hold the full moisture load of each batch for uninterrupted drying cycles.
Dry Screw Pumps
Oil-free vacuum pumps maintain chamber pressure between 0.06 and 0.4 mbar. Pull-down from atmospheric to process pressure in under 45 minutes.
Quality by the Numbers
Certifications & Standards
ISO 22000
Food Safety Management System - International standard ensuring systematic food safety controls across the entire production chain.
ISO 9001
Quality Management System - International standard for establishing a systematic approach to managing organizational processes and continuous improvement.
ISO 14001
Environmental Management System - Framework for minimizing environmental impact and ensuring compliance with applicable regulations.
ISO 45001
Occupational Health & Safety - International standard for preventing work-related injury and illness and providing safe working conditions.
ISO 10002
Customer Satisfaction - Guidelines for handling complaints effectively, enhancing customer satisfaction, and improving products and services.
HACCP
Hazard Analysis Critical Control Points - Preventive approach to food safety identifying and controlling biological, chemical, and physical hazards.
GMP
Good Manufacturing Practice - Ensures products are consistently produced and controlled according to quality standards.
Halal
Halal Certification - Certified compliance with Islamic dietary requirements for export to Muslim-majority markets.
Organic
Organic Certification - Verified organic production methods with no synthetic pesticides, fertilizers, or GMOs.