Date post: | 20-Mar-2017 |
Category: |
Education |
Upload: | meer-hossain |
View: | 247 times |
Download: | 6 times |
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.
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
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
AcidulationAcid Treatment
NaOH Option
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 BAcid Treatment
NaOH Option
• 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
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
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
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
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 S04=
Ash (product): 0.1 to 1%
Acid Treatment
NaOH Option
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
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
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
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
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
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
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
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
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
BlenderDrumming
andweighing
QC/QA Analysis
Acid Treatment
NaOH Option
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
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
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.