GEA, one of the world's largest suppliers of systems and components for the food, beverage and pharmaceutical industries, has made important adjustments to take pharmaceutical freeze-drying to an even higher level of sustainability. At ACHEMA 2024 in Frankfurt/Main, GEA presented the latest developments in the freeze-drying technology, which helps to optimize production processes, reduce environmental impact and save energy.
LYOAIR® cooling system with natural refrigerants and highly efficient compressors reduces environmental impact
One example is the LYOAIR cooling system®, which reduces the environmental impact of the freeze-drying process. Using 100 percent natural refrigerants and highly efficient compressors, the combination of an air circulation system with a carbon dioxide booster significantly reduces energy consumption compared to conventional systems.
Atmospheric spray freeze-drying reduces total energy consumption by almost 50 percent
In addition, atmospheric freeze-drying is a technique that can be used to produce so-called lyospheres® without the need for a vacuum. Initial prototypes, although not yet optimized for energy efficiency, have shown that total energy consumption can be reduced to less than 50 percent compared to conventional vacuum freeze-drying methods.
Microwave Freeze Drying enables continuous processing
GEA experts also presented the benefits of implementing fast and energy-efficient freeze-drying with microwaves. This technology not only offers advantages in terms of cost and supply efficiency, but also enables continuous processing instead of traditional batch processing.
GEA experts also presented at ACHEMA 2024 the benefits of implementing fast and energy-efficient freeze-drying with microwaves. This technology not only offers advantages in terms of cost and supply efficiency, but also enables continuous processing instead of traditional batch processing. (Photo: GEA)
LYOVAC® ECO Mode from GEA optimizes energy consumption
To counteract the high energy consumption of freeze dryers, GEA has introduced the LYOVAC® ECO Mode, which optimizes the freeze drying process with the help of dynamic temperature control of the condenser and regulation of the mushroom valve. This innovation enables significant energy savings without compromising product quality.
To counteract the high energy consumption of freeze dryers, GEA has introduced the LYOVAC® ECO Mode, which optimizes the freeze drying process with the help of dynamic temperature control of the condenser and regulation of the mushroom valve. This innovation enables significant energy savings without compromising product quality. (Photo: GEA)
Dr. Michael Golek
About GEA
GEA is one of the world’s largest suppliers of systems and components to the food, beverage and pharmaceutical industries.
The international technology group, founded in 1881, focuses on machinery and plants, as well as advanced process technology, components and comprehensive services. For instance, every second pharma separator for essential healthcare products such as vaccines or novel biopharmaceuticals is produced by GEA. In food, every fourth package of pasta or every third chicken nugget are processed with GEA technology.
With more than 18,000 employees, the group generated sales of about EUR 5.5 billion in more than 150 countries in the 2025 fiscal year. GEA plants, processes, components and services enhance the efficiency and sustainability of customers’ production. They contribute significantly to the reduction of CO2 emissions, plastic usage and food waste. In doing so, GEA makes a key contribution toward a sustainable future, in line with the company’s purpose: ”Engineering for a better world.”
GEA is listed on the German DAX, the European STOXX® Europe 600 Index and is also a constituent of the leading sustainability indices DAX 50 ESG, MSCI Global Sustainability and Dow Jones Best-in-Class World.
