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CASE STUDIES
The case studies below help to demonstrate our expertise and proficiency in the design and manufacture of innovative high vacuum systems and freeze dryers.
As manufacturers of bespoke high vacuum systems and a range of LyoDry freeze dryers, our specialist knowledge and experience helps our customers to overcome challenges and achieve the desired outcome.
This selection of case studies shows some of the innovative solutions we have provided and the results achieved.
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Explore our case studies below to learn more. Please contact us to discuss your high vacuum or freeze drying requirements and challenges.
CASE STUDY: FULL SCALE VACUUM DRYING TRIALS OF A WET TEST MATERIAL FOR NUCLEAR DECOMMISSIONING
CUSTOMER REQUIREMENTS:
To conduct full scale vacuum drying trials of a wet test material that was designed to reproduce certain characteristics of nuclear waste for Sellafield Ltd in collaboration with Nuclear Restoration Services Ltd (NRS) and The Decommissioning Alliance (TDA).
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A key objective was to establish the volume reduction of critical waste when dried to critical moisture content versus volume available for the next batch, using a test material inside a cuboidal Ductile Cast Iron Container (DCIC) using the Advanced Vacuum Drying System (AVDS).
Trials were required to define the operational envelope, including temperatures, drying times and the conditioning end point. This information would ultimately establish the maximum inventory of sludge per DCIC.
The project was a collaboration between MechaTech Systems Ltd, Sellafield Ltd, NRS Ltd and TDA.​​​
​​THE PROJECT:
Following the completion of a feasibility study, MechaTech Systems carried out vacuum drying trials for six months and treated approximately 7500 Kg of wet test material. The test material was loaded into the DCIC in 500 litre batches and dried under vacuum with heat, using the Advanced Vacuum Drying System.
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Throughout the project, data was recorded and analysed using level meters, sensors and cameras inside the DCIC to evaluate volume changes, the residual moisture content, the concentration of test material, splashing of test material inside the DCIC and evaporation rate.
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Upon completion of the project, MechaTech Systems provided a final detailed report to the customer which included the trials results, observations and key learning and the conclusion.​​​​
​​​HIGHLIGHTS:
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The Endpoint prediction method developed by MechaTech Systems provided real time indication of the moisture content of the Test Material inside the DCIC.
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The trials included cameras and lighting inside the DCIC which enabled observation via a live feed to key stakeholders. This proved invaluable not only as an observational tool, but also as a reporting method to stakeholders located hundreds of miles away. This greatly reduced the number of visits usually required by a project of this scale. Additionally, the data from the video images could be retained for easy access in future.​​​
​​​CUSTOMER FEEDBACK:
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“Many thanks for all the hard work in completing the trials for us.
It was a pleasure working with you all over the last 18 months. Your professionalism and active adoption of a fully collaborative way of working is an absolute credit to you all and was pivotal to success of the trials.”​​
Vacuum Drying Trials Equipment
Wet test material before vacuum drying
Dry test material after vacuum drying
Vacuum drying trials live feed
CASE STUDY: OIL DEGASSING & FILLING SYSTEM FOR ADAPTIVE OPTICS
CUSTOMER REQUIREMENTS:
A degassing and filling system for filling their product – a small fluid filled lens assembly - with degassed silicone oil for a small scale, pilot production line. The lenses are used for adjustable focus eyewear. This was a novel application and there was no ‘off the shelf’ solution available. Therefore, the client required a bespoke vacuum degassing and filling solution.
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SOLUTION:
MechaTech Systems were commissioned to provide the vacuum system used for degassing and filling. The silicone oil needed to be air free, so it needed to be degassed and filled under vacuum. The filling chamber was designed to be large enough to support filling 4 lenses in parallel. The lenses needed to be filled a rate of up to 24 per hour. The lenses had to be filled by a narrow bore pipe so the oil had to be pumped. The product was to be sealed while still under vacuum, requiring a linear mechanical motion.
Bespoke Oil Filling and Degassing System
CASE STUDY: VACUUM DRYING SYSTEM TO CONDITION NUCLEAR WASTE FOR NUCLEAR DECOMMISSIONING
CUSTOMER REQUIREMENTS:
To condition intermediate level nuclear waste in its final, disposable, transportable container, so that it is dry and stable for long term storage
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SOLUTION:
After conducting a series of in-house small scale vacuum drying trials, MechaTech Systems were commissioned to develop the prototype Advanced Vacuum Drying System (AVDS) by Nuclear Restoration Services Ltd (formerly Magnox). A Vacuum Conditioning Unit and two different types of Heating Station were designed, to accommodate two different types of Ductile Cast Iron Containers (cuboidal and cylindrical DCIC). In-house full scale trials were then carried out successfully.
The AVDS won the Magnox I4 Innovation Award, and MechaTech Systems were highly commended by the Nuclear Decommissioning Authority.
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To date (2025) MechaTech Systems have manufactured and supplied five Advanced Vacuum Drying Systems to UK nuclear decommissioning customers.
Advanced Vacuum Drying System for in-box conditioning of nuclear waste
CASE STUDY: FREEZE DRYER FOR ARCHAEOLOGICAL ARTEFACTS
CUSTOMER REQUIREMENTS:
English Heritage needed a Freeze Dryer to preserve archaeological artefacts, with a chamber that could accommodate bulky materials such as long planks of timber from ancient ships or even a neolithic body if required. For example, ancient bodies discovered in peat bogs, such as ‘Lindow Man’, have been preserved by freeze drying.
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SOLUTION:
The requirement was for a Freeze Dryer Condenser that was tried and tested, easy to operate, economical to service and as future proofed as possible in terms of replacement component parts. The LyoDry Midi (which directly replaces the old Edwards SuperModulyo Freeze Dryer) met all of these requirements with ease.
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The vacuum chamber, however, needed to accommodate long planks of wood - even a well preserved body which might be discovered in a peat bog, such as ‘Lindow Man’ mentioned above. Therefore the chamber was a bespoke design to enable horizontal orientation and a
length of 2m, larger than MTS’s core range of freeze dryer chambers. The chamber was designed to accommodate five stainless steel shelves, re-used from the client’s old freeze dryer, for bulk drying of several artefacts per batch. Both the condenser and the vacuum chamber were fitted with castors for portability.
The operating system includes a number of ‘recipes’ to enable controlled yet versatile freeze drying of products with differing process requirements – essential for the client’s diverse array of products. The system incorporates data logging to provide English Heritage with a secure audit trail, and alarm/event management to protect the product against potential product loss in the event of power or component failure. It also allows the operator to monitor the process in real time, remotely from a desktop PC, so the software was configured to allow remote operation.
LyoDry Midi Freeze Dryer with customised chamber for freeze drying longer than average samples