First, the raw material is cut to a manageable size, then washed to cleanse and de-grease. It then undergoes either the Type A or Type B process to further de-grease and de-mineralise.
The almost pure collagen is retained in readiness for extraction to gelatin. The further processes of extraction, filtration, concentration, drying, blending and packaging is the same for all gelatin raw materials.
The raw material is mixed with clean, warm water. By careful thermal control, the gelatin is gradually and gently released in the form of a liquor.
The liquor containing the gelatin is cleaned and polished by filtration. This may also involve centrifuging, ultra-filtration and ion exchange, all of which ensure the final removal of any inorganic material.
Most of the water is removed from the liquor by multi-stage vacuum evaporators. The rich gelatin liquor is now highly viscous, with a honey-like appearance. During this process it is subjected to high temperature flash sterilisation to prevent the risk of microbial contamination.
The warm gelatin solution is gelled by cooling in a votator, minced, and deposited as a bed onto an open-weave stainless steel belt, which passes through a drying chamber. A warm, dry air stream, which has been filtered and washed, is fed into the chamber and through the belt. This dries the gelatin.
When dry, gelatin has a moisture content of about 10%. The dry gelatin bed is then mechanically broken into particles.
Grinding, milling and blending
After microbiological and physical testing, the gelatin particles are ground, milled and blended to suit the end use and customer specifications.
The gelatin is further tested for final approval. It is then hygienically packed for storage and delivery.