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LyoCoN: Optimisation of freezing for vials

Freezing of many vials in a freeze dryer normally works out as a stochastic process. All vials will freeze only within a certain time frame, e.g. 1 hour. Furthermore, this crystallisation happens at different temperatures. Crystal structure and later drying behaviour will diverge.


For futher information:

The new developed technology LyoCoN (Controlled Nucleation) creates a controlled nucleation of all to be lyophilised vials. After loading of the freeze dryer, the cold ice condenser accumulates ice crystals (Fig. 1). Simultaneously the liquid product is cooled down close to the freezing point. In the next step a slight vacuum is established in the freeze dryer (Fig. 2). The external recipient is kept under atmospheric pressure. Finally a pressure equilibration between recipient and freeze dryer is started by opening a valve to the ice condenser. The air/gas from the recipient is injected into the ice condenser. The resulting ice fog infiltrates all vials (Fig. 3). These crystal nuclei immediately start homogeneous crystallisation in all vials.

After this, the freeze dryer is aerated completely to atmospheric pressure. Freezing of all crystallized vials can be continued in a conventional way, e.g. by further cooling down, annealing etc. 

Eiskristallakkumulation auf dem Eiskondensator
Herstellung eines Vakuums im Gefriertrockner
Injektion eines Eisnebels vom Eiskondensator in den Produktraum

Figure 1: Ice crystal accumulation at ice condenser.

Figure 2: Formation of a slight vacuum in the freeze dryer.  

Figure 3: Injection of an ice fog in the product chamber by pressure compensation between external recipient and ice condenser chamber.

LyoCoN – facts at a glance:

  • Formation of the ice fog with moisture out of the product, no external media necessary. GMP-compliant!
  • Simple basic principle since vacuum is already available; no overpressure design of the machine necessary
  • Therefore also ideal for smaller pilot units; retrofits feasible
  • No external waste media – which might contain drug/product - produced by LyoCoN

Contact Sales Switzerland

Mr. Jörg Kellerhals

Sales Manager

Contact Western Switzerland

Mrs. Véronique Miano

Sales representative Western Switzerland


We support our customers in implementation, maintenance and repair of all Kuhner products – efficiently and competently


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