By Dec Group
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Dec Group brings game-changing RHEOFREED® to pharmaceutical freeze-drying
Ecublens, Switzerland – World-leading materials handling and process specialist Dec Group has launched RHEOFREED®, a revolutionary mixer-type freeze dryer that represents a breakthrough in continuous lyophilization technology.
First unveiled at CPHI Worldwide in Frankfurt in October 2025, RHEOFREED® has now been formally added to Dec’s industry-leading portfolio following the establishment of a strategic partnership with Kobelco Eco Solutions of Japan.
By accelerating the drying process and reducing cycle times by up to 80% compared with conventional freeze-drying, RHEOFREED® sets new benchmarks for efficiency, scalability, and production agility in pharmaceutical manufacturing.
Overcoming traditional barriers
RHEOFREED® was developed in response to long-standing pharmaceutical industry concerns regarding the limitations of conventional lyophilization platforms—particularly their reliance on static drying and extended processing times. While shelf-type freeze dryers have long been considered the industry standard, they often suffer from slow and uneven drying performance and require high levels of operator expertise to achieve consistent results.
The key innovation behind RHEOFREED® is the integration of controlled mixing directly into the freeze-drying process. By introducing gentle agitation during drying, the system delivers a transformative improvement in drying efficiency, uniformity, and speed.
Contamination-free process design
Built on the proven Conical Dryer Blender (CDB) platform, RHEOFREED® redefines freeze-drying with a compact, efficient, and contamination-free design. The core of the system is a conical vessel equipped with external suction ports and no internal moving parts.
Using cold-resistant materials and significantly enlarged vacuum piping—up to five times the diameter used in conventional systems—the unit achieves the deep vacuum levels required for freeze-drying at temperatures between –20°C and –30°C.
The process begins by cooling the vessel and inserting an ultrasonic spray nozzle. Once vacuum conditions are established, liquid material is pumped into the vessel and instantly converted into frozen powder via spray freezing. The nozzle is then removed, and the vessel rotates during drying to ensure homogeneity. After drying, the powder is discharged directly, completing the cycle with minimal handling.
RHEOFREED® is GMP-compliant and designed for both small-scale testing and full-scale production, with capacities ranging from 0.1 to 100 liters. A compact 100 mL model is also available for pharmaceutical developers working with limited sample volumes.
Five game-changing features
RHEOFREED® revolutionizes lyophilization in five fundamental ways:
- Spray freezing without trays: An ultrasonic spray-freezing technique enables precise, continuous conversion of liquid into frozen powder without external freezing agents. This significantly reduces equipment footprint and freezing time.
- Dramatically faster drying: RHEOFREED® has demonstrated reductions in freeze-drying time of up to 80% compared with conventional shelf dryers (see graphic).
- Superior product quality: Continuous mixing ensures uniform moisture content, dramatically reducing residual solvent levels (for example, acetonitrile reduced from typical values of ~1,500 ppm to approximately 162 ppm), while preserving molecular integrity.
- Direct powder output: Dry powder is produced directly, eliminating the need for post-drying milling or crushing.
- Shortened overall process: Preparation, drying, discharge, and cleaning are streamlined. With no trays to load or wash, direct bottom-valve discharge, and a simple vessel design, overall processing time and operational complexity are significantly reduced.
Together, these capabilities position RHEOFREED® as a potential replacement for conventional shelf freeze dryers, establishing a new benchmark for performance, reliability, and innovation in pharmaceutical lyophilization.
About Dec Group
Founded in 1987, Dec Group is a Swiss based leading global provider of powder handling and process containment systems to the pharmaceutical, chemical, food and cosmetic industries.
Dec products offer a high level of safety for both operator and product. Their advanced system concepts, from the standard powder transfer system to highly complex integrated handling and processing equipment, allow clients to increase productivity while respecting stringent regulatory requirements.
Over the past years, Dec Group has carried out a significant expansion of its activities with the acquisition of specialized companies. The company today has divided its products into 5 distinct divisions: Powder Handling, Continuous Processing, Particle Size Reduction, Containment Solutions, and Filling Solutions. Together, these offer true end-to-end solutions from the raw material input to the final dosage form.
To learn more, visit: https://www.dec-group.net/
Resources
RHEOFREED®: A Game-Changing Innovation in Lyophilization Technology
Full-size mixer-type RHEOFREED® Freeze Dryer.
RHEOFREED® Small Scale Testing is designed for charge amounts up to 100 ml.
In testing, RHEOFREED® has shown significant time savings, reducing linear peptide process time from 100 hours to under 20 hours and reducing cyclic peptide freeze drying time from around 200+ hours to 56 hours.
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