CN104231943A - Method for manufacturing gelatin - Google Patents

Abstract

The invention provides a method for manufacturing gelatin, belonging to the technical field of protein colloid manufacturing. The manufacturing method of the gelatin is implemented by virtue of the following technical schemes: pre-soaking a leather material for 2 days by using lime water containing 1% of calcium oxide; cutting the leather material into small blocks, soaking into the 2-4% lime water, and periodically changing the lime water; transferring the leather material into a neutralization tank, and continuously stirring; removing calcium salt which is formed by combining collagen and calcium oxide in the leather material by using acid, and then removing the excess acid and generated salts by using clean water; firstly feeding a certain amount of water into a gelatin cooking pot, heating to the minimum gelatin cooking temperature, then pouring the water-washed leather material into the gelatin cooking pot, then feeding water again to ensure that the leather material is just immersed, and slowly heating to the gelatin cooking temperature; heating a gelatin solution in a concentration pan to ensure that moisture is evaporated, discharging the concentrated gelatin solution, and adding a certain amount of preservatives; and injecting the gelatin solution added with the preservatives into a gelatin freezing disc, and freezing into blocks in brine ice bath.

Description

The making method of gelatin

Technical field

The invention belongs to protein colloid manufacture technology field, particularly relate to a kind of making method of gelatin.

Background technology

The collagen protein that gelatin is the skin of animal, contain in bone, white connective tissue, through purifying and elementary hydrolysis post-treatment and obtained a kind of product.Gelatin is yellowish to yellow, the powder of translucent micro-band gloss or thin slice, without off-odor, and non-volatility.General gelatin is moisture below 16%, more stable at dry environment gelatin, and easily the moisture absorption is bacterially decomposed and goes bad in wet condition.Gelatin is when calcination, and deliquescing swells until carbonize, and releases the stink of a kind of special burning feather or ammonia.Gelatin indissoluble solution in cold water, but can absorb water and deliquescing, and very easily dissolve in the hot water.Gelatin is insoluble in the ordinary organic solvents such as gasoline, ethanol, chloroform.But dissolve in the organic acids such as acetic acid, Whitfield's ointment and phthalic acid, also dissolve in urea, thiocarbamide and the aqueous solution such as Potassium Bromide, potassiumiodide.

Gelatin is a kind of macromolecular compound, and its molecular weight is about 17500-450000.Gelatin can be divided into photographic gelatin, edible Gelatinum oxhide and technical gelatine by purposes.It is widely used in food, medicine, chemical industry, weaving, printing and dyeing, papermaking, match, five metals, furniture and sensitive materials etc. among conglomerate.

Summary of the invention

The invention provides a kind of making method of gelatin, the gelatin that the inventive method obtains is yellowish to yellow, the powder of translucent micro-band gloss or thin slice, without off-odor, and non-volatility.

The making method of gelatin of the present invention, is realized by following technical proposals:

(1) with the liming pre-soaking cladding 2 days containing 1% calcium oxide;

(2) cladding is cut into small pieces, immerses in the liming of 2-4%, and regularly replace liming, should first old liming be bled off when changing water, with clear water, cladding is washed once, then add new liming;

(3) cladding is proceeded in neutralization tank, and under constantly stirring, within every 30 minutes, change water once, totally 10 times, within later every 1 hour, change water once, the ratio of raw material and water should be 1: 6 at every turn, within 24 hours, completes and moves back ash;

(4) remove with acid the calcium salt that in cladding, collagen and calcium oxide combine, then remove unnecessary acid and the salt of generation with clear water;

(5) first discharge water to glue pot, be heated to endure glue minimum temperature, then the cladding washed is poured into glue pot, and then add water and make cladding just submergence, be slowly warming up to and endure glue temperature, when glue reaches certain weight proportion, namely glue is released from bottom, refill water and endure glue next time, corresponding raising temperature, more previous raising 5-10 degree;

(6) glue heats moisture is evaporated in concentrating pan, will concentrate glue and release, and add sanitas;

(7) gelatin solution adding sanitas is injected frozen glue dish, be placed in cryosel water-bath and be frozen into block.

Embodiment

Below by specific embodiment, the present invention is further illustrated.

Alkaline process produces gelatin except cladding, also needs the raw materials such as lime, hydrochloric acid, sulfuric acid, hydrogen peroxide, zinc sulfate.Take fresh pig skin as the consumption following (to produce 1 ton of gelatin juice) of waste gelatin.

One, raw material:

Fresh pig skin 5-6t lime contains calcium oxide 90% 3t hydrochloric acid industrial goods, 30% 150Kg hydrogen peroxide industrial goods, 30% 6Kg zinc sulfate industrial goods, 8Kg.

Two, major equipment:

1, ashpit is joined for preparing the liming of preimpregnation, liming.Be generally circular cement pit, band stirs.The size of joining ashpit is generally the 2-5 in liming pond doubly;

2, pre-soaking pit is generally square or rectangle cement pit, and Chi Gaoying is less than 1.5 meters, and water discharging valve is arranged at bottom, should arrange barrier before valve.Soak about 200 kilograms fresh hides by every cubic metre during design to calculate, generally arrange 2-4;

3, liming pond is generally square or rectangle cement pit, and be highly no more than 1.5 meters, water discharging valve is arranged at bottom, should arrange barrier before valve.Soak about 250 kilograms fresh hides by every cubic metre during design to calculate, according to the difference of skin raw material, 30-50 can be arranged;

4, neutralization tank is the band conical cement of stirring or Steel Vessel, and top is circular, and bottom is taper, and inwall should do Corrosion Protection of Fiber Reinforced Plastics.Should have the filter screen of a circular hole above tapered section, available stainless steel is made, to make that water flows out and cladding stays, by every cubic metre of process fresh hide material about 100 kilograms calculating during design.Generally arrange 2-4;

5, glue pot glue pot is aluminium or stainless steel jacket-heated vessel, and top is circular, and bottom is taper, is placed in the web plate of elongate holes above taper, and a perforated pipe is put at bowl center, is beneficial to glue convection current.In order to raw material unlikely compression when making to endure glue and be beneficial to quick plastic emitting, it is little greatly and highly that glue pot is usually designed to diameter, and the high and diameter ratio of straight flange is about 1: 1.8-2.By about the 500 kilograms designs of every cubic metre of process fresh hide material;

6, the strainer conical suction filter having rust steel to make, have porous sieve plate above tapering, sieve plate puts filter cloth, place filter cotton above filter cloth, filter cotton thickness is generally 35 millimeter, and filter cloth is let slip again in upper strata.Filter cotton thickness is 35 millimeters, then calculate by the light glue of every square metre of process per hour about 650 liters;

7, vaporizer generally can adopt the vacuum concentration pan of stainless steel, if better by economic benefits and social benefits vacuum-evaporator effect, comparable single-effect evaporator reduces energy consumption about 50%;

8, drying room adopts Chang Sui road formula drying room, has some dollies, car has the wooden cabinet of multi-layered soles part nylon screen in drying room.At the exit end of drying room, air filter is housed, gas blower and radiator element, enter gas blower after air filtration, after being heated to certain temperature, enter drying room with film reverse direction.Should there be venting port on the entrance end top of drying room.The import and export door of drying room should seal.

Owing to being generally divided into two stages during gelatin drying, wind speed and temperature are all different, therefore drying room should be divided into two sections to make two drying rooms;

9, dermatome can adopt dise knife, horizontal cutter combines to cut and carry out with machine, and midget plant also can with manually cutting skin;

10, refrigerator waters dish frozen glue and generally needs a refrigerator and a salt water tank, and small-sized gelatin factory Machine for making ice-sucker also can be used;

11, the universal hammer crusher of pulverizer.

Other equipment also have air compressor, basin, vacuum pump, slush pump etc.

Three, technological process

1, cladding arranges the object of cladding arrangement is make the raw materials quality of same lot number homogeneous, so that liming time consistency is to prepare the gelatin of same rank.Cladding arrange should note following some:

(1) different types of cladding (as dry hide and fresh hide, ox-hide and pigskin, Huang year skin and Corii Bubali, each thin skin of pachydermia, upper splitting and lower splitting, scalp, foot skin etc.) will separate, and the skin of different sites (buttocks, back, belly) also wants divisional processing;

(2) deoil: as Chuck Steak on fresh pig skin, application cutter scrapes off;

(3) live pig skin should first soak with the sodium sulfide solution of 5% dense liming or 0.5-1%, is removed by hair;

(4) skin of bulk will be cut into the strip of 10 centimetres wide;

(5) dry hide answers maceration before feeding intake.Salted hide first will remove salt, maceration in clear water.In order to prevent bacterium from corroding, water should be changed every day, steeping and getting final product deliquescing in about 3 days;

(6) when dry, fresh hide mixes, should by first for fresh hide row relax, in order to avoid rotten;

Cladding after collating sort, divides pond to soak in batches;

2, join grey unslaked lime first to add water and be made into thick slurry, general 1 kilogram of lime adds water 1.2-1.5 kilogram, then deposits about 15 days, thin up, crosses and filter to remove coarse particles, for subsequent use;

Join ash to carry out joining in ashpit, add water and thick slurry by desired concn, under constantly stirring, with slush pump, liming is squeezed into preimpregnation ashpit or liming pond;

3, the effect of pre-liming preimpregnation ash makes preliminary expansion, except blood stains, foul and stink in peeling; In addition because skin and lime effect make skin become stiffening, more easily cut off when cutting skin.Pre-liming is carried out in pre-soaking pit.Cladding about 2 days is soaked with the liming containing about 1% calcium oxide;

4, the object of chopping chopping is the speed accelerated liming and endure glue.General dermatome or manually cladding is cut into the block being less than 10 × 10cm2.Cut Pi Shiying to note cutting smaller as far as possible, but when should wash with liming, unlikely loss is limited; Same batch of material will be cut large novel is close, makes liming effect consistent;

5, the process of liming liming immersion skin raw material is called liming, and liming is the critical process of manufacturing of gelatin, has great impact to improving the quality of products.During liming, in liming, calcium hydroxide content general control is at 2-4%(proportion 1.015-1.035).During temperature height adopt lower concentration, when temperature is low adopt high density, during liming, the lime water yield should be about 4 times of wet pelt, and pH value controls at 12-12.5, and optimum liming temperature is about 10 degree, the highest can not more than 20 degree.Too high productive rate and the quality affecting gelatin of temperature.

Liming time length is decided by raw material type and range of product, with skin fresh and dried/thickness and temperature when soaking relevant.Generally the liming time of fresh pig skin is about 30 days, about about 2 months liming time of fresh ox-hide, dry ox-hide, dry pig splitting.When producing photographic gelatin, the liming time is longer.

Due to when liming, lime constantly acts on and reduces, and protein, the organism of leaching are more and more in water, must change liming to accelerate liming speed.Generally can according to the form below number of days periodic replacement liming.As found, liming is muddy or turn yellow, and should change in advance.First old liming should be bled off when changing ash, with clear water, cladding be washed once, then add new liming.

Liming number of times 1,2,3,4 and more than

Change the ash time (my god) 1-2,4-7,10-20,20-25

In whole liming operation, in order to improve liming efficiency, shorten the time, interval 8 hours application of compressed air is stirred once, requires to stir thoroughly.

Liming terminal generally can be determined according to following four kinds of methods

(1) micro-judgment: according to situations such as the expansion of skin, soft, color and lusters, judge liming terminal by feel is visual with practical experience;

(2) shrinkage temperature: the skin getting fritter liming, cleans with clear water, it is hung on together with thermometer in the cold water in same beaker, slowly heat.When skin longitudinally starts to shrink the shrinkage temperature that the temperature of curling is this cladding along it.Undressed fresh ox-hide shrinkage temperature is about 65 degree, and shrinkage temperature when liming completes reduces to about 40 degree;

(3) collagen pH value: when cladding collagen pH value is down to 4.75 from 6, show that liming completes;

(4) plastic emitting speed: get sample and endure glue, by enduring glue timing gelatin concentration, as then illustrated that liming terminal arrives when reaching specified requirement;

Liming, to the shrinkage temperature etc. that namely will check skin time certain, move back ash in time, otherwise liming overlong time then affects productive rate.After liming terminal arrives, bleed off by lime, cladding is proceeded to neutralization tank;

6, move back ash and move back the lime and other foreign material (as solubilising protein etc.) that grey object is the absorption of removal cladding.Move back ash to carry out in neutralization tank, under constantly stirring, within every 30 minutes, change water once, about totally 10 times.Within every 1 hour later, change water once.The ratio of raw material and water should be about 1: 6 at every turn, within general 24 hours, can complete and move back ash.Whether thoroughly move back ash, check with phenolphthalein test solution, get one piece of skin, drip several phenolphthalein indicators above skin, when in incarnadine (PH is about 9.5), namely illustrates that moving back ash can terminate, otherwise need continue to move back ash;

7, namely neutralization neutralization is made a return journey with acid and is allowanced for bark the calcium salt of middle collagen and calcium oxide combination.First add water and make cladding be immersed in water, start stirring, the hydrochloric acid soln diluting more than one times water is slowly added in water, keep PH to be about 3, neutralization start time, every 30 minutes acid addings once, after 4 hours, every 1 hour acid adding once, can add all acid in about 8 hours, continues to stir 4-8 hour.Neutralization the amount of using, fresh pig skin be wet pelt heavy about 4%, wet oxhide, dry pig splitting acid measure be about 8% of tare weight;

8, washing washing be in removing with clear water and time unnecessary acid and the salt of generation.Should not stop during washing to stir, within every 1 hour, change water number, change about 10 times altogether.After washing, the pH value of skin should meet requirement when enduring glue, is generally about 5.5;

9, endure glue to be heated together with water by raw material skin, the process pass on as gelatin that collagen is water-soluble is called endures glue.Enduring glue is one of key of manufacturing of gelatin, the general way adopting shunting to endure glue.First put a certain amount of water to glue pot, be heated to endure glue minimum temperature, then pour the cladding washed into glue pot, note hitting a man when he's down pine, do not make agglomerating.And then add water and make cladding just submergence, be slowly warming up to institute face and endure glue temperature.Attention can not add too much water, otherwise glue is too rare.PH when enduring glue should control about 5.5;

Endure glue to certain hour, when glue reaches certain weight proportion, namely release glue from bottom, refill water and carry out one and endure glue, corresponding raising temperature next time, generally more previous raising 5-10 degree, can boil for the last time.Should note not draining when putting glue, and speed wants slow, in order to avoid grease is mixed in glue.The condition of enduring glue process controls, and for fresh pig skin and fresh ox-hide, sees the following form:

(1) fresh pig skin number of channels: 1234567 gelatin Making programme three 2010-11-23 15:16 temperature (DEG C): about 55, about 65, about 75, about 85, about 95, about 100.About 4, about 5, about 5, about 6, about 6, about 3, suitable the time (hour):.Account for the per-cent (%) of total glue: 30-35,20-28,18-23,8-12,5-8,3-5 remarks: 1, glue proportion is 1.003-1.007.2, gel content is 4.5-7%.3,1-3 road is for taking a picture or edible Gelatinum oxhide, and 4 roads are edible or technical gelatine, and 5 roads are technical gelatine.6-7 road is hide glue;

(2) fresh ox-hide number of channels: 12345 temperature (DEG C): about 75, about 80, about 85, about 90, about 100 times (hour): about 7, about 7, about 8, about 9, the suitable per-cent (%) accounting for total glue: about 40, about 30, about 20, about 5, about 5

Remarks:

1, glue proportion is 1.002-1.007;

2, gel content is 4.5-7%;

3,1 road is for taking a picture or edible Gelatinum oxhide, and 2 roads are edible Gelatinum oxhide, and 3 roads are industrial bright magnetic, and 4-5 road is gelatin;

10, Filtration Filtration is the solid impurity in order to remove in glue, makes gelatin solution more limpid, and color reason is shallow, and this transparency to gelatin, color and luster have material impact.Generally suction method can be adopted.When filtering, gac or diatomaceous earth as filter aid can be added;

11, steam skin due to light glue generally only containing about 6% glue, moisture is too many, therefore moisture must be evaporated;

12, anticorrosion dense glue to be released in concentrating pan, add a certain amount of sanitas, the bacterial growth in glue can be prevented, ensure the quality of gelatin.General edible Gelatinum oxhide adds the hydrogen peroxide of dry glue amount about 1%, and technical gelatine and hide glue add the zinc sulfate of dry glue amount about 2%;

13, frozen glue is cut glue and is controlled between about-5 DEG C by icy salt solution, the gelatin solution adding sanitas is injected frozen glue dish, is placed in cryosel water-bath and is frozen into block.When cutting glue, the blob of viscose freezed is thinly sliced, thickness is wanted evenly, and thickness general control is below 5 millimeters;

14, in the dry screen cloth be placed in by the film of chopping on dolly, regularly (such as 1 hour) sends into drying room, correspondingly takes out car dryed product.

The drying of gelatin is divided into two sections, and the first stage is the constant rate of drying, and wind speed is about 3 meter per seconds, and temperature is 20-30 DEG C; First stage is falling rate of drying, and wind speed is 05-2 meter per second, and temperature is 30-40 DEG C.Wet films first sends into low temperature drying room, sends into high temperature drying room again when being dried to surperficial conjunctiva.General low and high temperature is dried each about 8 hours.Taking a sample to check film water content, getting final product discharging as reached 10% with next step.

15, packaging and mark

(1) pack: the packing of product divides inside and outside two-layer.The moistureproof Plastic film for food bag of internal layer, tightly must seal with hot pressing.Outer available gunnysack, chemical fibre bag, carton or wooden barrel.Every part net weight be no more than 50Kg wrapping material should be all clean, dry, moistureproof and firmly;

(2) indicate: all should there be obvious following mark in the front that every part product is packaged in, factory of factory name, name of product, lot number, net weight, date manufactured, edible bright magnetic should increase " foodstuff additive " printed words.The proof that quality product conformance with standard should be had in packing bag to require and standard number;

(3) transport: when transporting this product must with clean, ventilate and have the transportation means of Peng Gai, prevent from making moist and being heated, can not mix with dangerous product and load and transport;

(4) store: this product must be stored in warehouse that is clean, dry, that ventilate, must not air storage.Should prevent from being heated and Exposure to Sunlight.

Claims (1)

1. a making method for gelatin, is characterized in that comprising the following steps:

(1) with the liming pre-soaking cladding 2 days containing 1% calcium oxide;

(2) cladding is cut into small pieces, immerses in the liming of 2-4%, and regularly replace liming, should first old liming be bled off when changing water, with clear water, cladding is washed once, then add new liming;

(3) cladding is proceeded in neutralization tank, and under constantly stirring, within every 30 minutes, change water once, totally 10 times, within later every 1 hour, change water once, the ratio of raw material and water should be 1: 6 at every turn, within 24 hours, completes and moves back ash;

(4) remove with acid the calcium salt that in cladding, collagen and calcium oxide combine, then remove unnecessary acid and the salt of generation with clear water;

(5) first discharge water to glue pot, be heated to endure glue minimum temperature, then the cladding washed is poured into glue pot, and then add water and make cladding just submergence, be slowly warming up to and endure glue temperature, when glue reaches certain weight proportion, namely glue is released from bottom, refill water and endure glue next time, corresponding raising temperature, more previous raising 5-10 degree;

(6) glue heats moisture is evaporated in concentrating pan, will concentrate glue and release, and add sanitas;

(7) gelatin solution adding sanitas is injected frozen glue dish, be placed in cryosel water-bath and be frozen into block.