Apparatus and method for developing freeze drying protocols using small batches of product

1. An apparatus configured to simulate in a development freeze dryer containing a small sample of product in vials freezing and sublimation conditions of product in vials in a larger batch target freeze dryer, comprising:

a temperature controlled shelf;

a temperature controlled surface that is adjustable to simulate different temperature and heat transfer conditions;

said temperature controlled surface adapted to be in contact with at least one vial containing a product; and

a heat flux sensor measuring and controlling thermal transfer between the temperature controlled shelf and at least one vial containing a product, wherein a thermal conductor is adapted to be in contact with the temperature controlled surface and said at least one vial containing a product.

2. The apparatus of claim 1 wherein another heat flux sensor is mounted in a thermal path between the vial and the thermal conductor for measuring and controlling the heat flow to the vial.

3. The apparatus of claim 1 wherein the thermal conductor is formed of copper, stainless steel, aluminum, ceramic, paste, borosilicate glass and/or conductive rubber.

4. The apparatus of claim 1 wherein the thermal conductor is adjustable to provide contact with the vial.

5. The apparatus of claim 1 wherein the thermal conductor is a membrane that can expand and contract for contact with the edge vials or center vials.

6. The apparatus of claim 5 wherein the membrane is filled with a thermally conductive fluid that is temperature controlled.

7. The apparatus of claim 1 , wherein the temperature controlled surface is controlled by programmed steps or by tracking product temperature dynamically in response to changing temperatures or heat flow of any measured vial.

8. An apparatus for eliminating or minimizing the non-uniformity of edge vials compared to center vials during freezing or primary drying of product therein in a development freeze dryer containing a small sample of vials for simulating freezing or drying conditions in a larger batch target freeze dryer, said apparatus comprising:

a temperature controlled surface positioned to be in contact with the edge vials to control the temperature of the vials, wherein a thermal conductor is positioned between and in contact with the temperature controlled surface and the edge vials.

9. The apparatus of claim 8 wherein the thermal conductor is adjustable to make contact with edge vials located at different distances from the temperature controlled surface.

10. The apparatus of claim 9 wherein the thermal conductor is a contact block.

11. The apparatus of claim 8 , wherein the temperature controlled surface is controlled by programmed steps or by tracking product temperature dynamically in response to changing temperatures or heat flow of any measured vial.

12. An apparatus for eliminating or minimizing the non-uniformity of edge vials compared to center vials during freezing or primary drying of product therein in a freeze dryer, said apparatus comprising a thermal emulator positioned to be in contact with the edge vials to control the temperature thereof, wherein a thermal conductor is positioned between and in contact with the thermal emulator and the edge vials.

13. The apparatus of claim 12 wherein the thermal conductor is adjustable in size.

14. The apparatus of claim 12 , wherein the thermal emulator is controlled by programmed steps or by tracking product temperature dynamically in response to changing temperatures or heat flow of any measured vial.

15. A method for eliminating or minimizing the non-uniformity of edge vials compared to center vials during freezing or primary drying of product therein on a shelf of a freeze dryer, comprising installing on the freeze dryer shelf an apparatus comprising a temperature controlled surface adapted to be in contact with the edge vials to control the temperature thereof, wherein the temperature controlled surface surrounds the edge vials.

16. The method of claim 15 wherein a contact conductor is positioned between and in contact with the temperature controlled surface and the edge vials.

17. The method of claim 16 wherein the temperature controlled surface is adjustable in size.

18. The method of claim 15 further comprising controlling the temperature of the temperature controlled surface by programmed steps or by tracking product temperature dynamically in response to changing temperature or heat flow of any measured vial.