Atmospheric freeze-drying (AFD) is a relatively new freeze-drying technology without the need for a vacuum, making it easy to operate and cost-effective. Although there have been studies using AFD to dehydrate solid foods, there is currently no research on using AFD to dehydrate frozen liquids in pharmaceutical vials. In this study, several approaches were evaluated to enhance the atmospheric sublimation of water in pharmaceutical vials. Using −4 °C impinging jet airflow to dry frozen water samples in the vial, it was found that convective action significantly affected the sublimation rate. On this basis, a 3D-printed air-guide model was designed to improve airflow circulation in the vial, and it was found that the drying rate was highest when airflow energy loss was minimized, and airflow velocity at the sample surface was maximized. Additionally, the geometric characteristics of the vial also influenced the sublimation rate; vials with a larger bottom area and shorter height showed the highest sublimation rate. Increasing the vial’s bottom radius from 11 mm to 13 mm, under atmospheric pressure and using cold air at approximately −5 °C, reduced the drying time of 1 g of frozen water from 8.5 h to 6 h; each 5 mm height increase added 0.5 h to the drying time. Using cold air at −10 °C to dry 1 g of frozen water in a 5 mL vial, the combination of ultrasonic-induced energy (at a frequency of 39.46 kHz) and the air-guide model effectively reduced the sublimation time from 7 h to 5 h, compared to using only the air-guide model. However, this technique may be vulnerable to melting at the vial-transducer contact point, should the transducer be directly attached to the vials.
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