manufacture of gelatin

WELCOME TO MY PROJECT PRESENTATION

MEER HOSSAIN

ROLL : ASH1004022M

SESSION :2009-2010

DEPARTMENT OF APPLIED CHEMISTRY AND CHEMICAL ENGINEERING

NOAKHALI SCIENCE AND TECHNOLOGY UNIVERSITY

PROJECT TITLE:- GELATIN

SUPERVISOR

MD. SHAFIUL ISLAMLECTURERDEPT. OF APPLIED CHEMISTRY & CHEMICAL ENGINEERINGNOAKHALI SCIENCE AND TECHNOLOGY UNIVERSITY

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.

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

PROPERTIES It is tasteless and odourless ,vitreous, brittle solid faintly

yellow in colourGelling and water binding propertiesSurface properties Film-forming propertiesMicroencapsulationBioactive properties of hydrolysatesProtective colloidal action Amphoteric properties Antimicrobial properties

SOURCES Cattle Bones

Hides

Pig Skins

Fish

Agricultural Or Non-agricultural

Melon And Sorghum Bugs Insects

MANUFACTURE OF GELATINTwo Types Process are used To Manufacture of Gelatin :-

Type A

&

Type B.

Type A is Acidic Process And Type B is Basic Process.

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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

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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


Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


AcidulationAcid Treatment

NaOH Option

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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


Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Liming / Type BAcid Treatment

NaOH Option

• OBJECTIVES /

• Remove and neutralize excess lime

• Remove non-collagen impurities

• Adjust pH of the ossein slurry

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


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

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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)


Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Acid Treatment / Type A

>

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Ion Exchange


Deionize the thin gelatin liquor

Cations removed: Ca+2, Mg+2 and Fe+2

Anions removed: Cl- or S04=

Ash (product): 0.1 to 1%

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging




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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


pH Adjustment


Fine adjustment of the finished product pH

Final pH targets: 5-7 Caustic adjustment: NaOH

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Final Concentration


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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Sterilization


Ensure microbiological purity / product hygiene

Equipment: Direct steam injection / HTST

Temperature: 138° to 149° C Time: 8 to 16 seconds

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Chilled Extrusion


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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Drying


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

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Milling and Screening


Grind gelatin to a uniform size

Equipment: Cage mill Particle size: 8 to 30 mesh

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Blending

BlenderDrumming

andweighing

QC/QA Analysis

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Formulation

Component Selection

High Capacity Blender

QC/QA Analysis

Acid Treatment

NaOH Option

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Acidulation

Lime Treatment

Washing

Acidification

Acidulation

Washing

Extraction

Initial Filtration

Ion Exchange


Final Filtration

pH Adjustment

Final Concentration

Sterilization

Chilled Extrusion

Drying

Milling/Screening

Blending

Formulation

Final Packaging


Final Packaging

DrumsFIBCs

Small Bags

Acid Treatment

NaOH Option

ApplicationCommon examples of foods that contain gelatin are:

- Jellies

- Desserts

- Candies

- Trifles

- Aspic

- Marshmallows

- Gummy bears

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.

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.

CONCLUSIONFrom 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. If 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.

Thank you for your attention.

manufacture of gelatin

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