Lyophilization (aka freeze-drying) is a cornerstone of pharmaceutical and biotechnological advancements, enabling the stabilization, preservation, and enhanced bioavailability of critical materials.
Its elegant technique and stereotyped applications have been innovatively expanded to broader market applications over 60 years. These applications have enabled OFD to define new process controls to create stabilized products inside and outside the vial depending upon market, regulatory, and end-use.
At OFD Life Sciences, we’ve spent over 60 years refining our expertise in lyophilization, particularly outside the vial, opening new frontiers in material stability and performance.
From biopharma breakthroughs to government-backed medical innovations, we’ve lyophilized an array of unexpected and fascinating materials. Here are some of the most unique and high-impact applications we’ve tackled over the years.
1. 70+ Microbial Strains for Biopharma, Agriculture, and Beyond
Lyophilization plays a critical role in stabilizing microbial strains, ensuring they retain viability and efficacy over extended periods. OFD Life Sciences has successfully freeze-dried more than 70 different strains, spanning:
- Probiotics for human and animal health (even before the term “probiotic” was coined)
- Seed inoculants to improve plant growth and resilience (nitrogen-fixing bacteria to ice-nucleating bacteria for snowmaking and ice prevention in citrus field tests)
- Biopesticides for environmentally friendly pest control
- Aquamarine applications to enhance marine biology studies
By tailoring lyophilization parameters to each strain’s unique requirements, we enable long-term storage and easy reconstitution while preserving potency.
2. Platelets for Trauma and Emergency Medicine
One of the most impactful projects in our portfolio is the preservation of platelets—a critical advancement for trauma and battlefield medicine. In collaboration with Cellphire Therapeutics, DARPA and BARDA, OFD Life Sciences contributed to research, pre-clinical animal trials, and clinical phase 1a/1b trials, proving that freeze-dried platelets could be stabilized for up to two years, compared to the standard six-day shelf life of fresh platelets.
This innovation is now advancing through Phase III clinical trials. It has the potential to revolutionize transfusion medicine, reduce waste, and expand access to life-saving treatments for soldiers, trauma victims, and surgical patients.
3. The Nematode Experiment: Bringing Microscopic Life Back from Suspension
One of the more unconventional materials OFD Life Sciences has lyophilized is the nematode—a microscopic worm. Inspired by nature’s ability to preserve life in extreme conditions, we tested whether nematodes could survive lyophilization and be successfully rehydrated.
By fine-tuning the cryopreservative with freezing rates, drying parameters, and the use of protective sugars like trehalose and betaine, we successfully preserved a nematode, which returned to life upon rehydration. This experiment showcases lyophilization’s potential in biological preservation and regenerative science.
4. Regenerative Muscle Tissue for Facial Reconstruction
OFD Life Sciences contributed to the development of a protein-active lyophilized film designed for muscle tissue regeneration. Funded by the U.S. Army and the University of California, Berkeley, this technology aimed to assist in facial reconstruction following traumatic injuries.
By lyophilizing biologically active materials into a stable yet functional format, we helped enable advanced wound-healing solutions that could be stored, transported, and applied as needed for critical care.
5. Semi-Permeable Membrane Drying: Advancing Contamination Control and Scale-Up
OFD Life Sciences initiated the development of drying within semi-permeable membranes to protect against contamination and cleaning issues with microbials, paint pigments, and non-GRAS products.
We started with taking rolls of semi-permeable membranes used for water purification systems in 1990 and sealing them within our polybags to create a window for bulk drying. This novel concept was critical to drying multiple materials within the same dryer for development purposes and scale-up.
Expanding the Boundaries of Lyophilization
These projects are just a few of the many ways OFD Life Sciences has applied cutting-edge lyophilization techniques to solve real-world challenges.
Whether it’s extending the shelf life of critical biopharma materials, enhancing regenerative medicine, or stabilizing microbial applications, our expertise continues to unlock new possibilities.
Interested in what lyophilization could do for your material? Let’s explore the possibilities together.
