Gelatin is a solid, translucent, flavorless substance with a slightly yellowish or colorless color.
It is widely
used in cooking and the food industry due to its ability to gel liquids when
cooled, which is the process of transforming liquids into gel.
In addition
to its culinary uses, gelatin is also widely used in the manufacture of
pharmaceutical and cosmetic products.
It is
obtained mainly from collagen extracted from animal tissues, such as the skin,
bones, and cartilage of cattle and pigs.
Have you
ever wondered how gelatin is made?
In today's
video, we visit various industries to showcase the entire gelatin manufacturing
process.
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until the end.
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The history
of gelatin dates back to ancient times, when the use of gelatinous broths obtained by boiling animal bones and cartilage was already well established.
However, it
was not until the 17th century that gelatin began to be studied more
systematically, especially in France, as a source of nutrition for the poorest
population.
The
breakthrough came in the 19th century, with the development of industrial
techniques that allowed for large-scale production.
In 1845, in
the United States, Peter Cooper patented a process for making powdered gelatin,
which would later inspire the creation of the famous American brand Gelo in
1897.
During the
Second World War, gelatin played an important role, especially because it was
versatile, light, and rich in protein.
It was used
in soldiers' rations, mainly in the form of instant desserts and preserves.
Because it
was light, easy to store, and had a long shelf life, it was ideal for
transporting to the battlefield.
After the
Second World War, gelatin gained even more popularity, especially with the
growth of the food and pharmaceutical industries in the post-war period.
With
advances in the pharmaceutical industry, gelatin has become a standard material
for hard and soft capsules due to its ability to predictably dissolve in the
body.
Its use has
also grown as a carrier for vitamins, supplements, and tablet coatings.
But how is
gelatin made in the factory?
Gelatin
production begins in meat processing plants, where raw materials with a high
collagen content are selected.
This raw
material comes primarily from pigs and cattle, whose bones, skins, and
cartilage are rich in this valuable protein.
When the
animals are slaughtered, the cuts of meat are carefully selected, while the
skin and bones are separated and sent to the gelatin industry.
They are
transported in refrigerated trucks to the production plants, where they are
received and kept under strict temperature control.
This helps
prevent spoilage and ensures maximum product extraction.
The skins
and bones are washed with running water and sometimes with specific detergents.
This step
removes dirt and blood, residual fat, and unwanted tissue.
The cleaned
skins are cut into smaller strips.
This
increases the contact area and facilitates the action of the chemical reagents
and the collagen extraction process.
After
preparation, the raw material can be stored at low temperatures to prevent
decomposition.
The storage
time is short, as freshness is essential to ensure good yield and quality of
the gelatin.
The material
is then crushed and sent to the chemical pre-treatment area.
The smaller
the pieces, the easier the collagen will be to extract.
Depending on
the type of gelatin to be produced, there are two main treatment methods.
Type A is
the acid treatment used on pig skins.
The skins
are immersed in mild acid baths for 24 to 48 hours to break down the collagen
structures.
Type B is
the alkaline treatment used on beef bones and hides.
The material
is subjected to alkaline baths with lime, for example, for weeks or even
months.
These
processes help to break down the collagen bonds, making it soluble.
After the
chemical treatment comes the extraction phase, which is where the collagen
turns into gelatin.
Extraction
occurs through controlled heating in water, which breaks the structural bonds
of the collagen and converts it into soluble gelatin molecules.
The treated
raw material is placed in large tanks or reactors with heated water.
The
temperature normally varies between 50 and 60 °C, but there may be several
extractions in stages with progressively higher temperatures reaching up to 90 °C.
The process
lasts from a few hours to more than a day, depending on the desired quality of
the gelatin.
As the
collagen dissolves, a viscous and dense solution begins to form, similar to a
concentrated broth that contains several soluble proteins and other organic
compounds.
Then the
extraction phase begins.
The first
extraction is the lightest and produces a high-quality gelatin.
With more
transparency and greater gelling power.
The
subsequent extractions, carried out at higher temperatures, produce lower-quality
gelatin, which is used for technical or industrial applications.
Each
extraction results in a gelatin-rich liquid called extract.
This
extract, however, may still contain impurities, such as solid residues and
undissolved particles, and must undergo a purification process.
The extract
undergoes a rigorous filtration process.
The
extraction liquid is passed through metal mesh or fabric filters, such as
rotary drum filters.
These
filters retain larger particles such as undissolved collagen residues and bone,
and fiber residues.
It is like
straining a thick broth to remove the unwanted pieces.
After
filtration, the liquid may undergo pH and temperature corrections.
This
stabilizes the extracted gelatin, improves clarity, and prepares the liquid for
final purification.
This final
purification takes place in finer and more precise filters, such as activated
carbon filters to remove color and odors, and membrane filters that retain
microscopic particles.
This step
ensures that the gelatin remains clear without any unwanted odor or flavor.
The liquid
then goes to the evaporation concentration process.
It is heated
under reduced pressure to evaporate excess water without damaging the proteins.
This results
in a more concentrated and viscous liquid, almost like gelatin syrup.
After
concentration, the thick gelatin liquid is cooled until it forms a gelatinous
mass.
From there,
it can be formed into powdered gelatin, which begins with an extrusion process,
or sheet gelatin.
It is most
commonly used by pastry chefs and chefs for its practicality and purity.
In
extrusion, the gelled mass is pushed under light pressure through perforated dies
that work like a giant spaghetti pot.
This creates
thin, elongated strips known as gelatin noodles.
This shape
makes drying much easier because the strips have a high surface area and lose
water more quickly and evenly.
Conveyor
belts carry the strips directly to drying tunnels that use hot air to remove
moisture from the mass.
When
properly dried, the mass becomes brittle, so it is ground and sent to the
packaging area to form the gelatin sheets.
The gel mass
is spread in thin layers on cooled stainless-steel conveyors.
This turns
the liquid gelatin into a solid, thin, and elastic sheet.
The
thickness is controlled to form uniform sheets of about 2 millimeters.
The gelled
sheets are sent to drying tunnels.
They are
then cut into standard sizes and stacked.
Then they
are packaged.
The ground
gelatin is packaged in large bags and sent to the food industry, which will
process and package the final gelatin as we know it.
The gelatin
grains are ground until they become a fine powder, which is mixed with other
ingredients, such as sugar, flavorings, and colorings, which will give the
desired flavor and color to each type of gelatin.
Which will
be packaged in smaller packages and ready to be sent to the consumer market.
Because it
is rich in collagen, gelatin helps to strengthen bones and joints and
stimulates skin elasticity, in addition to strengthening hair and nails.
It also aids
digestion, helps hydrate tissues, and has a calming effect, even helping you
sleep.
In addition,
it is good for diets because it is low in calories and a great source of
protein, making it a perfect ally for those seeking a balanced diet.
And so,
thousands of tons of gelatin are produced around the world every year.
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