Ultrasound-assisted Atmospheric Freeze-Drying technology

Ultrasound-assisted Atmospheric Freeze Drying (US-AFD) technology is a cost-effective alternative to the frequently used high-cost freeze-drying methods. It can be implemented in a continuous process (without vacuum) and in a modular system (easy scalability).

We have developed a faster high-throughput process compared to air drying (above & below 0°C) with significantly better energy efficiency compared to both freeze-drying and air drying.

Our method can be used to dry materials of various size/form (i.e., whole, pieces, slices, particles, semi-liquids) with significant reduction in processing time and costs.

Technology

Highlights and advantages of US-AFD technology:

• Excellent product quality retention: because drying occurs at low temperature via sublimation, freezing temperature preserves structure, flavour, colour, and most nutrients much better than heat-based drying methods.
• Very long shelf life: removing up to ~95% of water prevents microbial growth and chemical degradation, allowing products to remain stable for years without refrigeration or preservatives.
• Near-original structure and fast rehydration: the process leaves a porous microstructure intact, enabling materials to rehydrate quickly and return close to their original form.
• Lightweight and logistics benefits: US-AFD drying reduces product weight by 70–90%, lowering transport costs and eliminating cold-chain requirements.
• Versatility and suitability for sensitive materials: US-AFD can be widely used for foods, pharmaceuticals, and biological products because it minimizes thermal damage to heat-sensitive compounds.

Applications

US-AFD drying is an economical alternative technology to freeze drying which is widely used where product stability, quality retention, and long shelf life are critical. In the food industry, it can preserve fruits, vegetables, coffee, ready meals, and specialty ingredients while maintaining flavour, nutrients, and rapid rehydration properties. In pharmaceuticals and biotechnology, it can stabilize vaccines, injectable drugs, probiotics, and diagnostic reagents by preventing degradation during storage and transport. The technology can also be applied as a medical research tool, including tissue preservation and laboratory sample preparation.

Emerging and secondary markets are expanding. These include pet food, nutraceuticals, and high-value functional ingredients, where premium quality justifies higher processing costs. Future development is expected in space missions, advanced biomaterials, and sustainable food systems, particularly for reducing food waste, enabling long-term storage without refrigeration, and supporting resilient supply chains in remote or climate-challenged regions.

Intellectual property

CSIRO currently holds IP in the form of granted patents in the USA, China & Australia and a pending European patent application. In addition, CSIRO holds unpublished operational know-how related to this technology.

Australian Patent No. 2018303341 "Drying process and apparatus"

United States Patent Application No. 16/631702 "Drying process and apparatus"

China Patent No. ZL 201880047674.3 "Drying process and apparatus"

Europe EP Pat Appl No. 18835253.8 "Drying Apparatus" pending.

The team

The team behind US-AFD technology combines deep engineering heritage with modern innovation. Leading the team are experienced experts in industrial drying technologies and ultrasonic systems and have adapted that know‑how to merge different techniques in most effective solution.

They have:

• Decades of R&D and manufacturing experience in drying technology from pharmaceutical and food processing sectors transferred to prototype machines.
• Strong research and development teams focused on precision control, efficient dehydration systems, and quality preservation.
• Backgrounds in automation, intelligent control and advanced process optimisation, ensuring reliability and performance at a consumer scale.