How much electricity does a 500 kg freeze dryer consume to freeze a batch?
A new seafood snack brand uses freeze-drying machines to process sea cucumber raw materials, launching ready-to-eat freeze-dried seafood products. Through low-temperature freeze-drying technology, the products retain the natural freshness and crisp texture of seafood, and contain no additives. Freeze-drying can control the rehydration rate of sea cucumbers to around 110%, with a protein retention rate exceeding 85%. After the products were sold through e-commerce platforms, the repurchase rate increased by 35%, and consumer feedback indicated that the taste was closer to fresh seafood than traditional dried products. To address the energy consumption control needs of manufacturing enterprises, the company's 500kg-class energy-saving freeze-drying solution has optimized energy conservation across the entire process and环节 (link/stage) from process design to equipment configuration, achieving overall energy savings of over 25%.
Core Energy-Saving Optimizations:
Compressor Heat Recovery System: Normally, when a compressor is running, high-temperature gas is discharged into the pipeline. The patented Five Intelligence heat recovery system collects and reuses this gas for heating, saving electricity. This technology avoids energy waste and reduces the external cooling burden. The exhaust gas, which is the heat source for the refrigeration system, is reused for heating. Patent No.: ZL2021232751762
Refrigeration Energy Saving: When the required cooling capacity decreases, the system automatically detects and reduces the compressor load from 100% to 75%, and then to 50%, to reduce energy consumption. Because the "heat recovery system" removes heat, the required cooling capacity is reduced, saving electricity and automatically reducing the workload; heat is removed, and the cooling load is reduced. Product Number: ZL2021233749505
Vacuum Design: Employs a dual vacuum system of pre-evacuation unit + maintenance unit, stably maintaining vacuum while reducing standby energy consumption by 15% compared to a single vacuum system. Simultaneously, a dry (oil-free) vacuum pump is selected, eliminating concerns about water vapor contamination of the vacuum oil, which could lead to poor vacuum sealing. Power consumption is only 35% of the installed power, saving 65% of the installed power. The perfect vacuum pressure and compact vacuum chamber design in the FD process ensures even lower power consumption due to extremely low vacuum leakage. Low maintenance, low noise, and low vibration.
High-efficiency silicone oil circulating heating: Temperature control accuracy reaches ±1℃, reducing heat loss by 12% compared to traditional electric heating plates.
Self-developed energy-saving temperature control technology: Combining pretreatment + segmented sublimation processes, helps companies shorten the drying cycle by approximately 20%.
Waste heat recovery design: Recovers excess heat from the condensation process for preheating, further reducing total energy consumption by 10%.
500kg-class solution core parameters
Parameter Items Specifications
Single Feed Capacity: 500kg (fresh material)
Maximum Water Capacity: 500kg/batch
Minimum Cold Trap Temperature: ≤-55℃
Nominal Total Power: 83kW
Total Power After Energy Saving: 58kW
Actual Average Operating Power: 29-40kW
Freeze-drying Time: 16H
Power Consumption per Unit of Dehydration: ≤1.85kWh/kg water
Based on our on-site testing for domestic processing enterprises, the Kemolo freeze dryer's 500kg capacity solution for processing fresh material can control the total power consumption per batch to within 600 kWh, saving over 50% compared to traditional equipment. The equipment price difference can be recovered through electricity cost savings within three to four years. If you would like a customized energy consumption calculation for your product, please contact us.
WhatsApp: +8615380024001
E-mail: sales@kemolo.com
https://www.kemolo.com/
https://www.liofilizador.com/
https://www.freeze-driers.com/
https://www.freezedryer.com.cn/
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