The degreased crushed bones are treated with weak solution of Hydrochloric acid for the demineralization which takes over a period of about seven to ten days. The calcium phosphates, carbonates & other minerals attached with bones dissolve in the acid to form Monocalcium phosphate leaving behind the organic collagen in the residual bone. This monocalcium phosphate liquid is precipitated by calcium hydroxide to produce Dicalcium Phosphate (DCP) as its byproduct which is a main constituent for the cattle & poultry feed. The treated residual bones are now known as Ossein.
The Ossein is then soaked in lime solution for a period of 60 -75 days depending on the size & quantity of bones for partial hydrolysis. This soaking makes the stock plump & pliable & dissolves soluble proteins like muscin & albumin. The limed soaked ossein are then washed with water to remove lime completely & then treated with dilute solution of weak acid to maintain pH in the range 5 – 6. Ossein after weak acid treatment is taken for Gelatin extraction.
Gelatine is then extracted in the form of weak solution of 5-6% for a period of 24 hours. This extraction is then mechanically filtered & passed through ion exchange (deashing system) for reduction of the dissolved ash in the gelatine solution. This ionized weak liquor of gelatine is then concentrated under vacuum through falling film & spiral evaporators to avoid any destruction to the basic skeleton structure of gelatine.
Concentrated gelatine liquor is then passed through sterilization system at temperature 138 -140 degree centigrade for 4 -5 seconds followed by extrusion for making noodles to facilitate proper drying of Gelatine in the next stage.
These gelatine noodles are then passed through various drying chambers maintained at various temperatures. Gelatin is dried very carefully with dehumidified air by gradual increase of temperature.
Dried gelatin is then crushed to required mesh size, vibro screened (to remove oversize & undersize particles) & then blended as per requirement of the customer & finally packed in laminated HDPE bags containing inner polythene liner.