| Gelatine
a raw material for capsules, foods, cosmetics and photographic films,
must be of the highest grade to give the finest product. Gelatine
is moisture and temperature sensitive by nature, therefore its manufacturing
necessitates incorporating the latest in drying technology to get
the desired quality in the final product.
The Process
The crushed bone passes through a number of phases before Gelatine
is produced. After "Degreasing" and "Demineralisation"
the Crushed bone is converted into an insoluble collagen, known
as Ossein- the basic raw material for Gelatine.
After pre-washing and soaking, Ossein
is transferred to the liming section. Liming is done under controlled
temperatures for a period of 45 or 90 days. After a special de-liming
process, the treated Ossein is ready for the complex gelatine extraction
process. This involves a series of filtration and concentration techniques.
Finally, the gelatine liquor is chilled in rotators. At low temperatures,
the solution of Gelatine transforms into solid gel. The gel is discharged
from the perforated outlet of the chiller in form of spaghetti noodles,
which are fed onto a continuously moving stainless steel belt dryer.
The Solution
Gelatine noodles from the chiller needs to be dehumidified with
gradual increase in temperature by sterilized dehumidified air,
till the moisture remains in the range of 10-12%. During the drying
process, gelatine passing slowly over a distance of 35 metres through
eight separate temperature zones, where the temperature is controlled
within ± 1°C. The air entering the dryer is conditioned
by means of dehumidifiers that have micro filters and pre-cooling
incorporated at the inlet. So no matter what the weather condition
is outside, the air entering the dryer is always at the same temperature
and moisture, as well as bacteria-free, throughout the year.
The cool, dry air absorbs the moisture from the product, bringing
down initial moisture content (IMC) from 70% to about 10-12% and
allowing surface hardening and rapid drying.
High level of precaution is required at this stage with respect
to temperature and sterilization as wrong temperature profile will
render melting of the gel, abnormality in solubility characteristics,
while any microbial contamination is undesirable considering the
application and biodegradability of Gelatine.
The dry gelatine, now in a stable condition, is stored in a separate
intermediate storage area where the process control laboratory samples
it before being finally crushed and blended according to the customer's
requirements.
Even in the finished goods warehouse, the gelatine is stored under
controlled conditions, so that it remains in excellent condition
until it leaves the factory.
The Bry-Air dehumidifier is the most economical and reliable method
of low temperature product drying - a sure prescription for a better
product!
Bry-Air Desiccant Dehumidifiers have been incorporated by many
organisations world over in the manufacturing process of gelatine.
Bry-Air Dehumidifiers removes moisture from the air, through a process
of continuous physical adsorption, and can effectively maintain
the most stringent humidity conditions required for Gelatine Drying
since they are capable of maintaining RH as low as 1% or even lower
at a constant level, regardless of ambient conditions.
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