The scope of this substance is quite extensive: starting from food manufacturing and ending with the industrial production of glue, film and textiles. Gelatin production is a long-term and labor-intensive process, which provides for certain requirements for raw materials and technologies.
Raw material preparation
The first step in producing quality gelatin is to pay attention to raw materials. The main requirement for quality is its good stickiness in a diluted state. To obtain such a substance, it is necessary that the raw material be high in collagen. In the manufacture of using animal bones, tendons, ligaments, cartilage, trimming skins.
Less commonly used fish stock and poultry bones. The material undergoes various processing before being put into production. First of all, manual sorting is carried out on a conveyor belt, as a result of which the bones are sorted by accessory, size and condition (raw or digested). Soft raw materials are sorted similarly to salted or fresh, according to the size of the fragments.
The bones undergo a degreasing process, for which they are filled with hot water (90-98aboutC) 10-15 centimeters above the level of the product. After that, they fall into a crushing machine, where they are crushed. When grinding fragments can be of various fractions. Large and medium sized and re-passed through the crusher.
The crushing of bones is carried out in order to maximize the surface area of the processed material. After selection and calibration, soft raw materials are washed, cleaned of dirt and impurities. Frozen - thawed in air or under running water at room temperature, salted thoroughly washed with water, dry soaked in milk of lime. After washing, all soft raw materials are crushed in a mezrozrezka.
Production technology
Further, the production of gelatin from all types of raw materials occurs according to a single scheme. The prepared crushed material undergoes an anesthesia process, which involves the removal of all proteins from the product, except collagen. For this, the raw material is placed in special containers, where it is poured with a solution of milk of lime for 25-45 days. During this time, the fluid is changed to lower the pH from 12 to 9.
The availability of raw materials is established by structure. It should be uniform, transparent and glassy. When these parameters are achieved, anesthesia is carried out: the resulting mass is washed with water (12-17 hours), then to neutralize it with hydrochloric acid (4-5 hours) and again with water for 3-3.5 hours.
The next stage is the cooking of gelatin, which is carried out at low temperatures (50-60 aboutC) with a gradual increase to 95-100 aboutC. The finished broth is preserved by sulfuric acid, filtered through cellulose filter presses, evaporated in vacuo and again treated with sulfuric acid. The final stage in production is its gelation (gelatinization).
To do this, the cooked and processed broth is loaded into a gelatinizer, where it turns into sheets or gelatin tape, which is dried in a tunnel-type dryer. Drying temperature at the beginning of the process should be around 25 aboutC, at the end can reach 50 aboutC. The production of edible gelatin involves drying lasting 12-15 hours, technical - about 20-25 hours.
Cost calculation
The costs of starting production are divided into one-time and permanent.The first involves capital investments made before the opening of the organization. Fixed costs, as a rule, fluctuate in a narrow range, occur at regular intervals throughout the entire period of work. One of the main one-time costs is for equipment for the production of gelatin.
Depending on the quality of the purchased devices, their service life can be from a year to 10 years. The following are the costs of the premises - the purchase or rental of the necessary square meters. They vary depending on the region where the production will be located. To reduce costs, it is better to look after the building somewhere outside the city. Fixed costs include the payment of energy, water, the purchase of raw materials, expenses for the salary of employees and so on. They can be calculated based on average market prices.
Payroll preparation
If we take as a basis that the company produces gelatin in the amount of 2000 tons per year, then with a three-shift schedule, about 120 employees will be needed. The average salary is 18 thousand rubles.
Based on this, 18 * 12 * 120 = 25920 thousand rubles a year will be the cost of labor. It should be remembered that of this amount, the employer must pay 30.2% to various funds. It turns out 25 920 thousand * 30.2% = 7 827.84 thousand rubles. As a result, the annual cost of workers will amount to 7 827.84 + 25920 = 33 747.84 thousand rubles.
Calculation of raw materials
Depending on what gelatin is made of, raw materials for its production will be selected. Bone cost: chicken - 20 rubles / kg, pork - 40-50 rubles / kg. The cost of soft raw materials: skins - 25 rubles / kg, mezdra - 8 rubles / kg, cartilage, tendons - 30 rubles / kg. Milk of lime costs about 1000 rubles per cubic meter, hydrochloric acid - about 50 rubles / liter. The properties of the gelatin at the outlet depend on the raw materials used. The most sticky it comes from cartilage and tendons.
Equipment calculation
The production line includes several parts: receiving module, preparatory, final and additional equipment. The receiving module includes: a conveyor - 5 pieces, a reactor for acceptance - 5 pieces, a sorting and grinding module, a module for degreasing.
The preparatory consists of a reactor for the preparation of raw materials - 4 pcs., 10 buffer tanks, a homogenizer - 3 pcs., An extractor - 2 pcs. The final module includes: condensation columns - 2 pieces, a vacuum evaporation tower - 2 pieces, a barometric condenser - 2 pieces, ejectors, cyclones, traps, separators, flems - 2 pieces each, drying - 2 pieces. As additional equipment are used: milk pumps - 18 pcs., Pumps for dense masses - 5 pcs., Piping - 1 pcs., Remotes, automation, sensors - 1 pc., Granulator - 1 pc.
The costs of opening a gelatin production business include: salary, cost of raw materials and equipment, utility bills and rent, other expenses.
Consider an approximate calculation of equipment costs:
- continuous drums (140 thousand rubles);
- belt conveyor (about 200-210 thousand rubles);
- capacities (100-200 thousand rubles)
- crushing machine (120 thousand rubles);
- apparatus for cooking gelatin;
- gelatinizer;
- filter presses (from 150 thousand rubles);
- apparatus for degreasing bones;
- drying machine (60-500 thousand rubles);
- vacuum evaporation apparatus (250 thousand rubles);
- packaging and packaging line (from 250 thousand to 2 million rubles)
- devices for monitoring the radiation purity of finished products and raw materials, as well as for quality control.
With a three-shift work schedule, the line can continuously produce up to 2000 tons of products in one year. To service such a production, it is necessary to hire up to 120 people.
Now consider the approximate calculation of the cost of raw materials and conclude:
- bones: beef - 10 rubles / kg; chicken - 2-20 rubles / kg;
- mezdra - 7.5 rubles / kg;
- pork skin - 20 rubles / kg;
- hydrochloric acid - 42 rubles / liter.
- milk of lime - 1000 rubles per cubic meter. m
The yield of gelatin from the bone can be 10%, therefore, from 10 tons of bone raw material, 1 ton of gelatin will be obtained.Therefore, the cost of raw materials for 160 tons of the final product will be approximately 20 million rubles. And the total costs will fluctuate around 29 million rubles. Wholesale kilogram of gelatin will cost about 180-250 rubles. Based on previous calculations, we can conclude that for two months with the release of 160 tons of gelatin, the income will be approximately 28 million rubles.
SES requirements
SES makes a rather strict requirement for the quality of gelatin, as this is a component used in food. Its production should be carried out in accordance with sanitary standards. All employees directly involved in the manufacture must have valid medical records with all marks on examinations and vaccinations. It is not allowed to find an employee at the factory in street clothes.
Each worker in the workshop should have replaceable sanitary clothing and shoes, as well as a hat that completely covers his hair. Employees should not be ill with infectious diseases. Workers with lesions of the skin with a rash or with festering wounds and cuts are not allowed in the workshop. All employees of the workshop must undergo a medical examination annually for infections.
Ready Gelatin Requirements
The main characteristic of gelatin in food production is its safety. In diluted form, gelatin is jelly. The higher the percentage of humidity of this jelly, the stricter the requirements for its storage. In gelatinous form, gelatin is a good environment for the development of pathogenic bacteria and molds.
To prevent infection, the premises where the substance is manufactured and stored must be constantly ventilated and disinfected with bactericidal lamps. The solution should not be stored for a long time, since this period affects its properties. The longer the storage time, the worse the properties of gelatin and the less gelatinous the product made from it will be.
Preparation of gelatin for production
In food production, gelatin is used for confectionery, jellies and jellies. Preparation includes soaking in cold water in a ratio of 1: 8 for 30-40 minutes, after which it is stirred and poured into a hot broth or compote in a thin stream. Next, the product, where gelatin is added, is boiled for several minutes, avoiding boiling. It cools first in air, then in the refrigerator. Gelatin production at this stage ends.
The properties
Gelatin is not only a carrier of photosensitive crystals. Its role is so diverse and important that only about 25 percent of this substance can be replaced with other materials. He has the following main qualities:
- a colloidal solution of gelatin prevents the "sticking" of some crystals of silver halide in the finished emulsion and in the production process; it is thanks to this property of this substance that crystals can be evenly distributed in the emulsion layer;
- when processing photographic materials facilitates the diffusion of solutions;
- crystals become more sensitive to light due to the high concentration of gelatin in the solution;
- gelatin, hardening, can provide the strength of the emulsion;
- has the ability to form a colloidal solution in water; the solution hardens upon cooling, and upon heating again becomes liquid; this property is very important for the production of emulsion, because the technological cycle consists of a stage of melting of the semi-finished product and freezing.
Gelatin directly affects the photographic process. Microimpurities in it can inhibit or accelerate the physical and chemical maturation of crystals. The former include calcium and nucleic acids, and the latter include sulfur compounds.
Composition
In gelatin, there is a very useful and important amino acid for the body called glycine. It is she who is responsible for the energy balance, which is necessary for good life, and also affects the functioning of the brain. In addition, the composition of the substance includes trace elements such as magnesium, calcium and phosphorus. Hydroxypproline and proline also benefit cartilage and connective tissue.Those who suffer from brittle bones need to take gelatin daily.
