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Manufacture of Gelatin

Manufacture of Gelatin. Marek Matusik.

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Manufacture of Gelatin

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  1. Manufacture of Gelatin Marek Matusik

  2. Gelatin is a translucent brittle solid substance, colorless or slightly yellow, nearly tasteless and odorless, extracted from the collagen inside animals' connective tissue. It has been commonly used in food, pharmaceutical, photography, and cosmetic manufacturing. Substances containing gelatin or functioning in a similar way are called gelatinous. Gelatin is an irreversibly hydrolyzed form of collagen. Gelatin is also known as E number E441. Gelatin is a protein produced bypartial 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. birefringence.

  3. Application Common examples of foods that contain gelatin are: - desserts - trifles - gummy bears - aspic - jellies - marshmallows - candies

  4. Gelatin may be used as a stabilizer, thickener, or texturizer in foods such as: - Yoghurt - Icecream - Margarine - Jam 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.

  5. Technical uses - Gelatin typically constitutes the shells of pharmaceutical capsules in order to make them easier to swallow. Hypromellose is the vegetarian counterpart to gelatin, but is more expensive to produce. - 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. Despite some efforts, no suitable substitutes with the stability and low cost of gelatin have been found. - Gelatin is closely related to bone glue and is used as a binder in match heads and sandpaper.

  6. Selected Raw Materials for the Manufacture of Gelatin Pig and cattle skin In the skin processing industry, theskin of slaughtered animals is firstthoroughly washed. The layer ofconnective tissue on the meat sideof the skin is then removed bymachine and the skin horizontallysplit. The intermediate layer, socalled hide split, consists mainly ofcollagen and is thus excellentlysuited to the manufacture of gelatin.The hide split is preservedusing salt or calcium hydroxide,which keeps it fresh until it is used in the gelatin manufacturingprocess.

  7. Bone chips. In meat processing, fresh bone isa by-product that is used in theproduction of gelatin. However,before it is used, it is subjected toa stringent pretreatment process.As a first step, bone is reduced topieces of between 5—10 mm. Theseare then degreased with hot water, dried and separated into variousparticle sizes.Potential bone adherenttissues are removed in thedegreasing process. The bone chipmaterial is then stored in silos untilrequired forproduction purposes. Demineralizationof bone chips. Treatment of this intermediate productwithdilute hydrochloric acid atlow temperature overseveral daysusing the reverse flow processremoves any phosphate containedin the bone.This process is known as"maceration" and thedemineralizedbone chips as "ossein". Thesurplus acid is then removed fromthe ossein bythorough washing.

  8. Raw Material Pretreatment. Acid processing. For gelatin of type A (acid), pigskinis normallyused as startingmaterial. Pigs, in contrast tocattle,are slaughtered at a relatively youngage. Since the skin of such younganimals is not ashighly cross-linked,a more gentle process thanthetedious alkaline process can beused; in this case, acid is used. Allthat is required is a one-day treatmentwith dilute acid, and thecollagen of the pigskin is renderedsoluble in warm water, a preconditionfor the subsequent extractionprocess. Any superfluous acid ispartlyneutralized and the remainingsalts washed outwith severalwashings of water. Ossein can alsobe processed to gelatin using thismethod with appropriate acid concentrationsand treatmenttimes.However, gelatin produced inthis way is relatively unimportant. Alkaline processing. Gelatin of type B (basic) is producedfromossein pretreated withalkali or from washed and cut hidesplits. In this process, the rawmaterials are treated for a periodof up to three months with calciumhydroxide, which is renewedseveral times during the period. Inthis process, thecollagen bondsare partially separated and any noncollagenousproteins and relatedsubstances removed. As an alternativeprocess, the rawmaterialcan be treated over a period of oneto two weeks with dilute sodiumhydroxide solution instead of calciumhydroxide. Subsequent to thisprocess, the treated raw material iswashed, neutralized by adding acid,and washed again to remove anyresidual salts.

  9. Process flowchart

  10. Thank you for yourattention.

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