How the right vacuum system transformed our customer’s freeze-dried pet food production

When it comes to pet treats, the freeze-dried variants are a favorite among pet owners. They offer a long shelf life, lightweight convenience and ability to retain essential nutrients. This type of pet food and treats are produced with a process called freeze drying or lyophilization.

At its core, freeze drying involves placing a frozen product in a vacuum chamber and gradually heating it to remove moisture via sublimation — a phase change where ice transitions directly into vapor, bypassing the liquid phase. This meticulous process ensures products can last 20–30 years when properly stored, making it invaluable in the pet food industry.

But achieving such precision requires reliable equipment, particularly the vacuum system, which is the heart of any freeze dryer.

Did you know the vacuum system plays a larger role in a freeze dryer's performance than you might expect? Ensuring the vacuum installation maintains consistent pressure and optimal conditions throughout the cycle is essential to achieving high-quality end products.

However, not all vacuum systems are up to the task and outdated technologies often fall short in demanding applications like pet treat production. Older industrial freeze dryers typically use oil-sealed rotary vane pumps paired with rotary lobe boosters. While these set-ups have served the industry for decades, they come with significant drawbacks, especially in high-contamination applications:

• Frequent maintenance: Oil changes are required monthly, leading to downtime and increased labor.
• High costs: Each pump can generate over 60 gallons of oil waste annually, costing thousands in maintenance.
• Short lifespan: Process contamination often causes premature wear, requiring costly rebuilds and replacements.

A forward-thinking customer facing challenges with their aging rotary vane pumps sought a modern, efficient solution. Enter the Atlas Copco GHS900 VSD+ oil-sealed rotary screw pump and DRB3000 VSD+ booster pumps, a combination that revolutionized their freeze-drying operations.

1. Integrated Precision:
   • Fully integrated with the customer’s PLC via Modbus TCP/IP, these pumps offer precise control over the pump-down curve and target vacuum levels.

1. Extended Maintenance Intervals:
   • Unlike traditional systems requiring monthly oil changes, the GHS900 VSD+ operates efficiently with oil changes needed only once a year. This is thanks to effective oil temperature control and post-drying purge cycles, which reduce oil contamination.

1. Energy and Cost Savings:
   • Over a trial period, the customer saw an average savings of $22,000 per year per dryer in reduced maintenance and energy costs.
   • The advanced variable speed technology optimizes energy consumption, ensuring the system only uses power as needed.

Thanks to this upgrade, the customer has replaced all their old pumps and now runs every dryer in their facility with Atlas Copco's innovative vacuum solutions. The result? Enhanced operational reliability, lower environmental impact, and significant cost savings.

Atlas Copco Vacuum North America is committed to driving efficiency and innovation in freeze drying and beyond. Whether you're producing freeze-dried pet treats or other lyophilized goods, our cutting-edge vacuum solutions can help you achieve superior performance and profitability.

Contact us today to learn more about how Atlas Copco can transform your operations!