Manufacture of gelatin

This slide contains Definition, Composition, Properties, Source, Manufacture and Application of Gelatin

1. Welcome To My Project Presentation Meer Hossain Roll : ASH1004022M Session :2009-2010 Department of Applied Chemistry and Chemical Engineering Noakhali Science and Technology University

2. P roject Title: - Gelatin Supervisor Md. Shafiul Islam Lecturer Dept. of Applied Chemistry & Chemical Engineering Noakhali Science and Technology University

3. Gelatin is an organic nitrogenous colloidal protein produced by partial hydrolysis of collagen extracted from connective tissues of animals such as the domesticated bovines, porcines and equines. The natural molecular bonds between individual collagen strands are broken down into a form that rearranges more easily. Gelatin melts when heated and solidifies when cooled again. Together with water it forms a semi-solid colloidal gel.

4. Chemical Composition Gelatins normally contain about 15% of water and 1-4 % of inorganic salts. Gelatin, like its precursor collagen, contains Carbon ………………………….. 15% Hydrogen ……………………….. 26% Nitrogen ……………………..….. 18% Oxygen ………………………….. 25% Sulfur ………………………….. 0.1% Phosphorus ………………………. traces

5. Properties It is tasteless and odourless ,vitreous, brittle solid faintly yellow in colour Gelling and water binding properties Surface properties Film-forming properties Microencapsulation Bioactive properties of hydrolysates Protective colloidal action Amphoteric properties Antimicrobial properties

6. Sources Cattle Bones Hides Pig Skins Fish Agricultural Or Non-agricultural Melon And Sorghum Bugs Insects

7. Manufacture of Gelatin Two Types Process are used To Manufacture of Gelatin :- Type A & Type B. Type A is Acidic Process And Type B is Basic Process.

8. 8 Typical Characteristics Fat content = 1 to 2.5% Size range = 1/8 to 5/8” Mineral/protein ratio = 1.9 - 2.1 Moisture content = 6 to 9% Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Acid Treatment NaOH Option

9. 9 Objectives Produce ossein by Removing the mineral content of the bone Initiate the hydrolysis of collagen Remove non-collagen impurities Conditions Hcl concentration: 4-6% Acidulation time: 5-7 days Acidulation temperature: 50° to 65° F Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Acidulation Acid Treatment NaOH Option

10. 10 Conditions Lime slurry concentration: Over saturated Lime slurry pH: Approximately 12.5 Liming time: 25-70 days Liming temperature: 50-70° F Agitation: Daily Objectives Continue to hydrolyze collagen Continue to remove non-collagen impurities Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Liming / Type B Acid Treatment NaOH Option

11. Objectives / Remove and neutralize excess lime Remove non-collagen impurities Adjust pH of the ossein slurry 11 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Washing / Acidification Conditions Wash time: 24 to 48 hours Agitation: Vigorous Water temperature: 45° to 70° F Neutralizing acids: Hydrochloric & sulfuric Target pH: 5 to 7 Acid Treatment NaOH Option

12. 12 Conditions Traditional Treatment: Sulfuric acid at pH = 1.0 - 2.0 Treatment time: = 6 hours Washing: Rinse up to 24 hours to a pH of 2.8 - 3.2 Alkaline pre-treatment option (under review) pH is maintained at 13 or greater with NaOH for 3 hours (prior to acid treatment) Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Acid Treatment / Type A > Acid Treatment NaOH Option

13. 13 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Gelatin Extraction Objective Solubilize hydrolyzed collagen (gelatin) from the ossein Conditions Water purity: Demineralized Procedure: Series of extractions with increasing water temperatures Water temperatures: 120° to 200° F Conditioning time: 1 to 6 hours / extraction Number of extractions: 4 to 6 Acid Treatment NaOH Option

14. 14 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Initial Filtration Objective / Conditions Clarify dilute gelatin solution Protect ion exchange system Vertical leaf pressure filter Pre-coated with diatomaceous earth and cellulose Gelatin concentration: 4-6% Acid Treatment NaOH Option

15. 15 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Ion Exchange Objective / Conditions Deionize the thin gelatin liquor Cations removed: Ca +2 , Mg +2 and Fe +2 Anions removed: Cl - or S0 4 = Ash (product): 0.1 to 1% Acid Treatment NaOH Option

16. 16 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Initial Concentration Objective / Conditions Concentrate the thin gelatin liquor Evaporator type: Multiple effect rising film or plate and frame Concentration target: 15-25% Output temperature: 115° F to 150° F Acid Treatment NaOH Option

17. 17 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Final Filtration Objectives / Conditions Clarify concentrated gelatin solution Remove additional coagulated protein and particulate Plate and flame pressure filters Cellulose / diatomaceous earth filter pads Acid Treatment NaOH Option

18. 18 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS pH Adjustment Objective / Conditions Fine adjustment of the finished product pH Final pH targets: 5-7 Caustic adjustment: NaOH Acid Treatment NaOH Option

19. 19 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Final Concentration Objective / Conditions Concentrate the thick gelatin liquor Evaporator type: Thin film / wiped surface or plate and frame multiple effect Output temperature: 115° to 125° F Concentration target: 25 to 50% (viscosity dependent) Acid Treatment NaOH Option

20. 20 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Sterilization Objective / Conditions Ensure microbiological purity / product hygiene Equipment: Direct steam injection / HTST Temperature: 138° to 149° C Time: 8 to 16 seconds Acid Treatment NaOH Option

21. 21 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Chilled Extrusion Objective / Conditions Increase the surface area of the gel mass Glycol - cooled heat exchanger / extruder Temperature: Approx. 70° F Noodle dimensions: 1’ to 2’ long / 1/8” thick Acid Treatment NaOH Option

22. 22 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Drying Objective / Conditions Produce a dry, stable product Air quality: Heated, dehumidified and filtered Temperature gradient: 80° to 160° F Time: 1 - 3 hours Moisture content (gelatin): 10 to 12% Acid Treatment NaOH Option

23. 23 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Milling and Screening Objective / Conditions Grind gelatin to a uniform size Equipment: Cage mill Particle size: 8 to 30 mesh Acid Treatment NaOH Option

24. 24 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Blending Blender Drumming and weighing QC/QA Analysis Acid Treatment NaOH Option

25. 25 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Formulation Component Selection High Capacity Blender QC/QA Analysis Acid Treatment NaOH Option

26. 26 Bone /Type B Bone/Type A Acidulation Lime Treatment Washing Acidification Acidulation Washing Extraction Initial Filtration Ion Exchange Initial Concentration Final Filtration pH Adjustment Final Concentration Sterilization Chilled Extrusion Drying Milling/Screening Blending Formulation Final Packaging GELATIN MANUFACTURING PROCESS Final Packaging Drums FIBCs Small Bags Acid Treatment NaOH Option

27. Application Common examples of foods that contain gelatin are : - Jellies - Desserts - Candies - Trifles - Aspic - Marshmallow s - Gummy bears

28. Gelatin may be used as a stabilizer, thickener, or texturizer in foods such as : - Ice cream - Jam - Yoghurt - Margarine Gelatin is used for the clarification of juices, such as apple juice, and of vinegar. Isinglass, from the swim bladders of fish, is still in use as a fining agent for wine and beer.

29. Technical uses - Gelatin typically constitutes the shells of pharmaceutical capsules in order to make them easier to swallow. - Animal glues such as hide glue are essentially unrefined gelatin - It is used to hold silver halide crystals in an emulsion in virtually all photographic films and photographic papers.. - Gelatin is closely related to bone glue and is used as a binder in match heads and sandpaper.

30. Conclusion From the present phenomena ,it is seen that gelatin has ample use in cosmetic, pharmaceutical and food industry. In bangladesh only opsonin pharmaceuticals ltd. Produce low grade gelatin whice is insufficient for bangladesh . Being insufficient in the source of gelatin, it is imported from foreign country every year.Due to this activity, a huge amount of money has to be allocated. But if we give attention to the source of our country, we can figure out this problem. For example: Cattle bone is A non-negligible source of gelatin in our country. I f good govt. Policy is shown and characterized cattle bone can be congenial to produce gelatin by proper guidance and collaboration. If strongly handed, gelatin production can be added to our economy. As for me, i’m aspirant to the scope for gelatin market in Bangladesh.

31. Thank you for your attention .