500kg energy-saving freeze dryer delivers under 600kWh per batch power consumption, cutting energy use over 50% vs traditional model by patented heat recovery, dry vacuum pump, and optimized process.
Kemolo Freeze-Drying Case Study
An emerging seafood snack brand uses our freeze dryer to process sea cucumber raw materials, launching ready-to-eat freeze-dried seafood products. Using low-temperature freeze-drying technology, the products retain the natural umami and crisp texture of seafood without any additives. Freeze-drying maintains the rehydration rate of sea cucumber at approximately 110%, with a protein retention rate of over 85%. After being sold through e-commerce platforms, the product’s repurchase rate increased by 35%, and consumer feedback indicates a taste closer to fresh products compared with traditional dried products.
To meet manufacturers’ demand for energy consumption control, we have launched a 500kg energy-saving freeze-drying solution with optimized energy efficiency across the entire process, from process design to equipment configuration, achieving an overall energy saving of over 25%.
Core Energy-Saving Optimizations
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Compressor Heat Recovery System
During normal compressor operation, high-temperature gas is typically discharged into pipelines. The
patented Kemolo heat recovery system captures and reuses this heat for heating, reducing power consumption. This technology eliminates energy waste and lowers external cooling loads. Waste heat from the refrigeration system exhaust is recovered and reused for heating.
Patent No.: ZL202123275176.2
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Energy-Efficient Refrigeration
When cooling demand decreases, the system automatically detects and reduces compressor load from 100% to 75% and further to 50%, cutting energy use. Since the heat recovery system removes excess heat, required cooling capacity is reduced, lowering power consumption and automatically lightening the operating load.
Patent No.: ZL202123374950.5
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Optimized Vacuum System Design
A dual vacuum system (roughing pump set + holding pump set) stably maintains vacuum level while reducing standby energy consumption by 15% compared with a single vacuum system. Dry (oil-free) vacuum pumps are used to avoid water vapor contamination of vacuum oil, which can cause poor vacuum sealing. Power consumption is only 35% of installed power, saving 65%. The compact vacuum chamber design for FD processes ensures extremely low vacuum leakage and minimal power demand, with low maintenance, low noise, and low vibration.
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High-Efficiency Silicone Oil Circulation Heating
Temperature control accuracy reaches ±1℃, reducing heat loss by 12% compared with traditional electric heating plates.
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In-House Energy-Saving Temperature Control Process
Combined with pretreatment and staged sublimation processes, the drying cycle is shortened by approximately 20%.
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Waste Heat Recovery Design
Excess heat from the condensation process is recovered for preheating, further reducing total energy consumption by 10%.
| Item |
Specification |
| Single Batch Loading Capacity |
500kg (raw material) |
| Maximum Water Capture Capacity |
500kg/batch |
| Minimum Cold Trap Temperature |
≤ -55℃ |
| Rated Total Power |
83kW |
| Total Power After Energy Saving |
58kW |
| Actual Average Operating Power |
29–40kW |
| Freeze-Drying Duration |
16H |
| Energy Consumption Per kg of Water Removed |
≤ 1.85kWh/kg water |
According to on-site tests conducted for domestic processing enterprises, the
Kemolo 500kg freeze dryer can limit total power consumption per batch to under 600 kWh when processing raw materials, saving more than 50% energy compared with traditional equipment. The price difference of the equipment can be recovered through saved electricity costs within three to four years.
For a customized energy consumption calculation tailored to your products, please contact us.
