WO2015002622A1 - High-bloom grade gelatin manufacturing process from poultry (chicken, turkey, duck, goose) tissues - Google Patents
High-bloom grade gelatin manufacturing process from poultry (chicken, turkey, duck, goose) tissues Download PDFInfo
- Publication number
- WO2015002622A1 WO2015002622A1 PCT/TR2014/000179 TR2014000179W WO2015002622A1 WO 2015002622 A1 WO2015002622 A1 WO 2015002622A1 TR 2014000179 W TR2014000179 W TR 2014000179W WO 2015002622 A1 WO2015002622 A1 WO 2015002622A1
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- WIPO (PCT)
- Prior art keywords
- gelatin
- tissues
- value
- poultry
- gelatin solution
- Prior art date
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09H—PREPARATION OF GLUE OR GELATINE
- C09H3/00—Isolation of glue or gelatine from raw materials, e.g. by extracting, by heating
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
- A23J1/00—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites
- A23J1/10—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from hair, feathers, horn, skins, leather, bones, or the like
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
- A23J3/00—Working-up of proteins for foodstuffs
- A23J3/04—Animal proteins
- A23J3/06—Gelatine
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
- A23J3/00—Working-up of proteins for foodstuffs
- A23J3/30—Working-up of proteins for foodstuffs by hydrolysis
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
- C08H1/00—Macromolecular products derived from proteins
- C08H1/06—Macromolecular products derived from proteins derived from horn, hoofs, hair, skin or leather
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L89/00—Compositions of proteins; Compositions of derivatives thereof
- C08L89/04—Products derived from waste materials, e.g. horn, hoof or hair
- C08L89/06—Products derived from waste materials, e.g. horn, hoof or hair derived from leather or skin, e.g. gelatin
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D189/00—Coating compositions based on proteins; Coating compositions based on derivatives thereof
- C09D189/04—Products derived from waste materials, e.g. horn, hoof or hair
- C09D189/06—Products derived from waste materials, e.g. horn, hoof or hair derived from leather or skin
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09H—PREPARATION OF GLUE OR GELATINE
- C09H3/00—Isolation of glue or gelatine from raw materials, e.g. by extracting, by heating
- C09H3/02—Purification of solutions of gelatine
Definitions
- the invention is related to production of gelatin from the collagen that exists in the tissues of poultry (chicken, turkey, duck, goose).
- the mentioned technique ensures low energy and water consumption to manufacture high-bloom grade gelatin within short process lead times at optimized physical conditions by using specified chemicals herein.
- Chicken skin and bones are ground to a size of 25-30 mm.
- Sulphuric acid is added to the ground chicken skin and bones at 4% max. By weight and in the first phase waited for 24 hours, acid is replaced by fresh acid after 24 hours and waited for another 24 hours.
- the objective of the present invention is to obtain high bloom grade (over 100), odorles, transparent and fat free gelatin from poultry (chicken, turkey, duck, goose) tissues with a total process lead time under 60 hours.
- the present invention cosists of the folowing process steps
- poutry tissues are ground to a size between 2 mm and 10 mm at a temperature range of 5 °C (deggre celcius) to -4 °C, 0 °C is preferred.
- Ph reducer having a concentration of 2-4 % by weight with an initial waiting period of 24 hours and the acid was replaced by fresh acid after 24 hours and waited for an other 24 hours.
- Ph value of poultry tissues is increased to 2.5-3.0 by rinsing with water, 2.7 is preferred.
- NH 4 OH+(NH4) 2 S0 4 alkaline buffer solution is added to the poultry tissues in between 0.5% to 1% by weight then waited for 0.5 hour to 1 hour time period to increase the Ph to 3.5-4.5 range, preferrably to 4.0.
- hydrolysis is carried out at multiple temperatures (55 °C, 65 °C, 75 °C, 85 °C and 95 °C).
- One of the important step of the present invention 90% of the collagen existing in the poultry tissues is hydrolyized at two temperature points i.e. 61 °C and 81 °C by using the alkaline buffer solution.
- the hyrolysis takes place ina jacket heater which ensures homogenous heating without direct touch of poultry tissues to heating source. Hydrolysis at two temperature points decreases the operating costs, durations (lead times) and equipment requirements.
- First hydrolysis temperature is between 55 °C and 65 °C, preferrably 61 °C and the second hydrolysis temperature is between 70 °C and 90 °C, preferrably 81 °C.
- the obtained gelatin solutions are stored in seperate tanks.
- Duration of each hydrolysis step is 6 to 10 hours.
- 35-40 units fat, 15-20 units residue and 50-40 units gelatin solution are typically obtained from a 100 units poultry tissue by weight.
- the gelatin solution obtained by the hydrolysis of collagen is then filtered by a filter that has cotton with 1:0.1 volume ratio.
- the water content of the obtained gelatin solution is 96-97%
- the water content of the gelatin solution is decreased to 20-30% at temperature values between 40 °C to 80 °C by using reverse osmosis filtration.
- the concentrated gelatin solution is sequentially passed through cationic, anionic and mixed bed resin at temperatures between 40 °C and 70 °C, preferrably 61 °C.
- the salt content of the gelatin solution is decreased to 300-500 ppm at Ph value under its isoelectric point (4.5-6.5 Ph value range is preferred).
- gelatin concentration is dried on a band conveyor tunnel at temperatures between 20 °C to 50 °C, preferrably 30 °C.
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- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Biochemistry (AREA)
- Food Science & Technology (AREA)
- Medicinal Chemistry (AREA)
- Nutrition Science (AREA)
- Zoology (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Dermatology (AREA)
- Wood Science & Technology (AREA)
- Jellies, Jams, And Syrups (AREA)
- Meat, Egg Or Seafood Products (AREA)
Abstract
The invention is related to production of high-bloom grade gelatin from the poultry tissues (chicken, turkey, duck, goose). The goal of the invention is to develop an environment friendly process ensuring low operating cost to manufacture colorless, odourless, high grade gelatin (over 100 bloom) in line with islamic requirements from the poultry tissues.
Description
Description
High-Bloom Grade Gelatin Manufacturing Process from Poultry (chicken, turkey, duck, goose) Tissues
The invention is related to production of gelatin from the collagen that exists in the tissues of poultry (chicken, turkey, duck, goose).
The mentioned technique ensures low energy and water consumption to manufacture high-bloom grade gelatin within short process lead times at optimized physical conditions by using specified chemicals herein.
No previous invention and technology has been detected in Turkey regading gelatin manufacturing from poultry tissues.
According to the Description of GB2207137 (A);
i. Chicken skin and bones are ground to a size of 25-30 mm.
ii. Sulphuric acid is added to the ground chicken skin and bones at 4% max. By weight and in the first phase waited for 24 hours, acid is replaced by fresh acid after 24 hours and waited for another 24 hours.
iii. After acidic maceration the product is washed with water and hydrolysis is carried out at 55, 65, 75, 85 and 95 °C degrees. Each extraction step is accomplished in 4-5 hours, which means it takes 20-25 hours in total for the entire hydrolysis phase to be completed.
iv. Following the 5 micron ultra filtration, product is dried by air.
Acccording to the aforesaid invention (GB2207137(A)) approximately 120 hours are required to obtain gelatin from raw material by consuming significant amount of water and energy.
The objective of the present invention is to obtain high bloom grade (over 100), odorles, transparent and fat free gelatin from poultry (chicken, turkey, duck, goose) tissues with a total process lead time under 60 hours.
The process flow diagram of the present invention is given in the attachment.
Figure-1: Process Flow Diagram
l
Detailed Description of the Present Invention
The present invention cosists of the folowing process steps;
Decreasing the Ph Value of the Poultry (chicken, turkey, duck, goose) Tissues and Rinsing
In the prior art, chicken skins and bones were ground to size between 25 mm and 30 mm
In the present invention poutry tissues are ground to a size between 2 mm and 10 mm at a temperature range of 5 °C (deggre celcius) to -4 °C, 0 °C is preferred.
After grinding the tissues to the above mentioned size range, water and hyrochloric acid at 30-33% concentration is added to tissues. The amount of water is 60 % of the tissues by weight and amount of hydrochloric acid (30-33%) is 2-3% of the tissues by weight. The waiting period is 10 to 12 hours at Ph value between 1.0 to 1.5.
In the description of GB2207137 (A) 1989-01-25 sulphuric acid was used as Ph reducer having a concentration of 2-4 % by weight with an initial waiting period of 24 hours and the acid was replaced by fresh acid after 24 hours and waited for an other 24 hours.
Due to the very low Ph values obtained by sulphuric acid, fat tissues would stick on the skin and bone particules which cause extraction problems and in addition more salt would occur while increasing the Ph value to certain point before hydrolysis and these would increase the process cost and decrease the gelatin quality.
By the present invention, decreased Ph value of poultry tissues (between 1.0 to 1.5) is increased to 2.5-3.0 by rinsing with water, 2.7 is preferred.
Increasing the Ph value of Poultry Tissues by Alkaline Buffer Solution and Rinsing
NH4OH+(NH4)2S04 alkaline buffer solution is added to the poultry tissues in between 0.5% to 1% by weight then waited for 0.5 hour to 1 hour time period to increase the Ph to 3.5-4.5 range, preferrably to 4.0.
After increasing the Ph value of poultry tissues to 3.5 to 4.5 range, salt is removed from the poultry tissues by rinsing with water at temperature 15 °C to 25 °C. Ph value shall not go over 5.5 during rinsing process.
Hydrolysis of Ph Adjusted Poultry Tissues
As it is mentioned in GB2207137 (A) 1989-01-25 description, hydrolysis is carried out at multiple temperatures (55 °C, 65 °C, 75 °C, 85 °C and 95 °C).
One of the important step of the present invention, 90% of the collagen existing in the poultry tissues is hydrolyized at two temperature points i.e. 61 °C and 81 °C by using the alkaline buffer solution.
The hyrolysis takes place ina jacket heater which ensures homogenous heating without direct touch of poultry tissues to heating source. Hydrolysis at two temperature points decreases the operating costs, durations (lead times) and equipment requirements.
First hydrolysis temperature is between 55 °C and 65 °C, preferrably 61 °C and the second hydrolysis temperature is between 70 °C and 90 °C, preferrably 81 °C.
The obtained gelatin solutions are stored in seperate tanks.
Duration of each hydrolysis step is 6 to 10 hours.
Filtration of Gelatin Solution from Hydrolyized Poultry Tissues
Three products are obtained as a result of the hydrolysis process. These are fat, residue (cohed skin and bone particules) and gelatin solution.
35-40 units fat, 15-20 units residue and 50-40 units gelatin solution are typically obtained from a 100 units poultry tissue by weight.
The gelatin solution obtained by the hydrolysis of collagen is then filtered by a filter that has cotton with 1:0.1 volume ratio.
Concentration of the the Filtered Gelatin Solution
After the hydrolysis of poultry tissues, the water content of the obtained gelatin solution is 96-97%
The water content of the gelatin solution is decreased to 20-30% at temperature values between 40 °C to 80 °C by using reverse osmosis filtration.
Typical application for the removal of excess water is evaporation. However this method takes longer times and is more expensive compared to the above mentioned technique. In addition to these, long operating time at high temperatures decreases the quality of gelatin.
Deionization of Concentrated Gelatin Solution
The concentrated gelatin solution is sequentially passed through cationic, anionic and mixed bed resin at temperatures between 40 °C and 70 °C, preferrably 61 °C. The salt content of the gelatin solution is decreased to 300-500 ppm at Ph value under its isoelectric point (4.5-6.5 Ph value range is preferred).
Drying Process of Deionized Gelatin Solution
After removing the excess water of the gelatin solution by reverse osmosis and deionization, remaining gelatin concentration is dried on a band conveyor tunnel at temperatures between 20 °C to 50 °C, preferrably 30 °C.
Claims
Claims
The invention claimed is; A metod that ensures manufacturing high bloom grade gelatin featuring the following steps:
· Decreasing the Ph Value of the Poultry Tissues and Rinsing
• Increasing the Ph Value of Poultry Tissues by Alkaline Buffer Solution and Rinsing
• Hydrolysis of Ph Value Adjusted Poultry Tissues
• Filtration of Gelatin Solution from Hydrolyized Poultry Tissues
• Concentration of Filtered Gelatin Solution
· Deionization of Concentrated Gelatin Solution
• Drying of Deionized Gelatin Solution
Process step "Decreasing the Ph Value of the Poultry Tissues and Rinsing" stated in Claim 1 features; grinding the poultry tissues to a size between 2.0 mm and 10.0 mm at temperatures between 5 NH4OH+(NH4)2S04 to -4 °C, preferrably 0 °C, adjusting the Ph value of the tissues at 1.0 to 1.5 by adding water at a ratio 60 % by weight and hydrochloric acid (30-33%) at a ratio 2-3% by weight and waiting 10 to 12 hours and then setting the Ph value between 2.5 to 3.0 preferrably 2.7 by rinsing the processed poultry tissues by water.
Process step "Increasing the Ph value of Poultry Tissues by Alkaline Buffer Solution and Rinsing" stated in claim 1 features; adding NH4OH+(NH4)2S04 alkaline buffer solution to poultry tissues at a ratio between 0.5% and 1.0% by weight and increasing the Ph value to 3.5-4.5 (preferrably 4.0) from 2.5-3.0. After waiting 0.5 hour to 1 hour, poultry tissues shall be rinsed by water while Ph value is kept under 5.5.
Process step "Hydrolysis of Ph Value Adjusted Poultry Tissues" stated in claim 1 features; hydrolization of poultry tissues two times at two temperature points between 45 °C and 90 °C where 61 °C and 81 °C is preferred, in a jacket heater with a heating period 6 to 10 hours.
Process step "Filtration of Gelatin Solution from Hydrolyized Poultry Tissues" stated in claim 1 features; removing the poultry tissues (cooked skin and bone particles) and fat from the gelatin solution after the hydrolysis by filtration using cotton at a ratio 1:0.1 by volume.
Process step "Concentration of Filtered Gelatin Solution" stated in claim 1 features; removing of water from fat free gelatin solution at temperature range of 40 °C to 80 °C by reverse osmosis filtration
Process step "Deionization of Concentrated Gelatin Solution" stated in claim 1 features; passing the dehyrated gelatin solution sequentially through the cationic, anionic and mixed resin beds at a temperature range between 40 °C to 70 °C having a Ph value between 4.5-6.5
Process step "Drying of Deionized Gelatin Solution" stated in claim 1 features; applying the concentrated gelatin solution on a band conveyor tunnel and drying the concentrated solution by dry air at a temperature between 20 °C to 50 °C, preferrably 30 °C.
The gelatin manufactured according to the stated claims has a bloom value over 100 which can be used in food, health and medical industry.
The gelatin of claim 9 wherein said gelatin is turned into hygienic kits by being applied to pads and tampons, including tampons that are used to suck the blood and stop bleading in medical procedures, interventions.
The gelatin of claim 9 wherein said gelatin is used to seal the cooked or fresh vegetables and meat products by forming a solid gelatin layer over them and make the cooked or fresh vegetable and meat products packed for sale.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR201306257 | 2013-05-27 | ||
| TR2013/06257 | 2013-05-27 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2015002622A1 true WO2015002622A1 (en) | 2015-01-08 |
| WO2015002622A4 WO2015002622A4 (en) | 2015-02-19 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2014/000179 WO2015002622A1 (en) | 2013-05-27 | 2014-05-21 | High-bloom grade gelatin manufacturing process from poultry (chicken, turkey, duck, goose) tissues |
Country Status (1)
| Country | Link |
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| WO (1) | WO2015002622A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2019091502A1 (en) * | 2017-11-09 | 2019-05-16 | Tomas Bata University In Zlin | Biotechnology-based production of food gelatine from poultry by-products |
| WO2021146240A1 (en) * | 2020-01-13 | 2021-07-22 | Cargill, Incorporated | Turkey collagen hydrolysates and methods of making |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB561966A (en) * | 1942-07-01 | 1944-06-13 | Frederick Arthur Isherwood | Improvements in and relating to the preservation and storage of perishable materials |
| US4367242A (en) * | 1981-02-06 | 1983-01-04 | General Foods Corporation | Roast poultry coating mix and process |
| GB2207137A (en) * | 1987-07-24 | 1989-01-25 | Budapesti Baromfifeldolgozo Va | Process for the preparation high bloom-grade gelatine from poultry by-products |
| EP0323790A1 (en) * | 1987-12-30 | 1989-07-12 | Elf Sanofi | Continuous process for obtaining gelatin from bone powder, and gelatin obtained |
| US6359191B1 (en) * | 1997-04-04 | 2002-03-19 | Symbio Herborn Group Gmbh & Co. | Vaginal tampon and process for producing the same |
| WO2002072723A2 (en) * | 2001-03-08 | 2002-09-19 | Banner Pharmacaps, Inc. | Gelatin manufacturing process and product |
| US20030044456A1 (en) * | 1998-10-23 | 2003-03-06 | Nippon Meat Packers, Inc. | Hypoallergenic gelatin |
-
2014
- 2014-05-21 WO PCT/TR2014/000179 patent/WO2015002622A1/en active Application Filing
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB561966A (en) * | 1942-07-01 | 1944-06-13 | Frederick Arthur Isherwood | Improvements in and relating to the preservation and storage of perishable materials |
| US4367242A (en) * | 1981-02-06 | 1983-01-04 | General Foods Corporation | Roast poultry coating mix and process |
| GB2207137A (en) * | 1987-07-24 | 1989-01-25 | Budapesti Baromfifeldolgozo Va | Process for the preparation high bloom-grade gelatine from poultry by-products |
| EP0323790A1 (en) * | 1987-12-30 | 1989-07-12 | Elf Sanofi | Continuous process for obtaining gelatin from bone powder, and gelatin obtained |
| US6359191B1 (en) * | 1997-04-04 | 2002-03-19 | Symbio Herborn Group Gmbh & Co. | Vaginal tampon and process for producing the same |
| US20030044456A1 (en) * | 1998-10-23 | 2003-03-06 | Nippon Meat Packers, Inc. | Hypoallergenic gelatin |
| WO2002072723A2 (en) * | 2001-03-08 | 2002-09-19 | Banner Pharmacaps, Inc. | Gelatin manufacturing process and product |
Non-Patent Citations (1)
| Title |
|---|
| F. RAFIEIAN ET AL.: "Optimization of gelatin extraction from chicken deboner residue using RSM method", JOURNAL OF FOOD SCIENCE TECHNOLOGY, vol. 50, no. 2, 1 March 2013 (2013-03-01) - 1 April 2013 (2013-04-01), pages 374 - 380, XP002732411 * |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2019091502A1 (en) * | 2017-11-09 | 2019-05-16 | Tomas Bata University In Zlin | Biotechnology-based production of food gelatine from poultry by-products |
| WO2021146240A1 (en) * | 2020-01-13 | 2021-07-22 | Cargill, Incorporated | Turkey collagen hydrolysates and methods of making |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2015002622A4 (en) | 2015-02-19 |
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