Once the raw materials have been thoroughly cleaned, different process steps are carried out to obtain gelatin depending on the type of raw material. There are two basic types of process: acidic and alkaline
Alkaline process - for gelatin type B: Here, the raw material (bovine hide) is subjected to several weeks of treatment with alkali. This enables the collagen structure to be gently transformed. The collagen it contains, now softened by the pretreatment, can now be extracted using warm water.
The pretreated raw materials are then treated with warm water in an extraction process, the gelatin being removed in a number of process steps. The first gelatin extracts, obtained at relatively low temperatures, are rather firm and have a light color. The extraction solutions contain approximately 4% gelatin. After these first extracts, the remaining material is treated with fresh water but at a higher temperature. This sequence is continued until all the gelatin has been extracted into solution.
In this step, the gelatin solution obtained from the extraction process is placed in high-performance filters where it is freed from residual traces of fat from the raw material and from any insoluble particles. Pre coat filters are then employed to remove fine-particle contamination with the help of Kieselgur (diatomaceous earth), followed by filtration through cellulose plates (as used in the beverage industry).
Purification of the gelatin is completed by removing any salts present using an ion exchange process.
In the concentration step, multi-stage vacuum evaporators are used to remove part of the water from the dilute gelatin extraction solution in a gentle process. In this way, the gelatin becomes viscous and honey-like in consistency.
Subsequent to the concentration step, the gelatin solution is heat-sterilized for safety purposes; it is then cooled and allowed to set. The gelatin is now in the form of "gelatin crystal the gelatin is dried with sterile, pre-washed. pre-dried and filtered air. At the end of the drier, the now hard and brittle gelatin is broken up, milled and stored in the warehouse until required for further use. Individual batches are only released for further use on the successful completion of physical, chemical and bacteriological testing in the lab.
Milling and sieving processing steps. Here, the dried gelatin is customized to the requirements of individual customers, sacks or bags and after final release from the lab, the products are transported to the customers.
After blending according to requirements of individual customers gelatin powder backing after lab analysis the products are transported to the customers.
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