- Introduction and historical review
- Advantages and disadvantages of freeze drying
- Structure and function of a freeze dryer
- The three phases of freeze-drying process
- Process monitoring and optimisation
Increased Efficiency through Optimisation of Lyophilisation Cycles and PAT
(Dr Andrea Weiland-Waibel)
- CQA and critical process Parameters
- Freeze drying: scale-up and validation
- Process control strategies
Impact of the new Annex 1
(Dr Frank Sielaff)
- EU GMP Annex 1 - Effects on Lyo products
- GMP questions during inspections
- Experiences from the perspective of an inspector
Simulation of Lyophilization & CCIT
(Dr Andrea Weiland-Waibel)
- Simulation techniques and models for the optimisation of Lyophilisation
- Introduction to Container Closure Integrity Testing (CCIT) methods and their importance
- Integration of CCIT in quality control and Quality assurance
Lyophilization Technology- Design Requirements and Technical Solutions
(Anthony J Cannon)
- Main components of a lyo (chamber, condenser, refrigeration skid, vacuum skid, shelves, etc.)
- Purpose of these components
- Design criteria of these components (temperature homogeneity, cooling and heating capacity, sublimation capacity and gas flow, etc.)
Lyophilizer in Aseptic Production Lines - Challenges and Chances
(Kristien Janssen)
- Automatic Loading and Unloading of Freeze Dryers
- FD cycles: monitoring and challenges
- Turn-over times
- Lyoplus
- Steps towards higher sustainability
Aseptic Process Simulation (Media Fill)
(Heide Nagel)
- Media Fill Design
- Worst Case Parameter for Media Fill
- Validation of lyophilisation processes with Media Fill
- Requirements for Media Fill
Spray Freeze Drying
(Bernhard Luy)
- Aseptic generation of homogenous, free-flowing lyophilized bulk material
- Spray freezing and dynamic rotary freeze drying
- Process characteristics and product properties
- Case Studies and industrial applications for parenterals
Qualification and Testing of Freeze Dryers
(Maik Guttzeit)
- QbD requirements for successful freeze dryer Projects
- Qualification strategies and critical test requirements
- Involvement of suppliers in the qualification process
Supercritical CO2 Technology as an enabling Approach for the Drying of Biopharmaceuticals
(Luis Padrela)
- Drying of biomolecules
- Atomization
- Supercritical CO2-based Methods
- Particle size Control
- Stabilization
- Economic and aseptic considerations
WORKSHOPS
On the third conference day, you will have the opportunity to take part in several parallel workshops. For that purpose, several lyophilizers will be available at GEA. Experienced GEA experts will lead you in small groups, providing an intensive experience and directly applicable Know-how.
Hands-on demonstration of production scale freeze dryer design and functions
This workshop will provide each participant with an overview of a state-of-the-art production-scale freeze drying system, including system configuration. Also, a small scale production freeze dryer that is applicable to be integrated into the VARIOSYS® Platform will be demonstrated.
Fundamentals of freeze drying, cycle development and scale-up
For effective freeze drying, each product requires a unique recipe (formulation); these formulations are initially developed on a laboratory or pilot-scale unit and it is imperative that formulation development takes both product characteristics and the limitations of pilot and production machines into account. This workshop will examine the procedures and consequences of process development and scale-up.
Live demonstration of automated loading and unloading systems
Demonstration of fully operational fixed and robotic load/unload system. Additionally, it will be possible to look at a system with special features, including online moisture control.
Workshop tour including visit of shelf manufacturing area, freeze dryer testing as well as simulation and system integration.
Innovations in freeze drying applications
This workshop will focus on processing Microwave Freeze Drying, as well as the use of environmentally friendly cooling systems and technologies for controlled nucleation and continuous freeze drying.
It is highly recommended that you bring your own safety shoes, if available!
Free transfers on 23 October 2025: A shuttle bus will bring you to Cologne Central Station at approximately 15:15 h. From Cologne Central Station, frequent airport connections are available.