Solutions for the production of gelatine

Solutions for the production of gelatine

ITALPROGETTI blends the traditional art of leather treatment and filtration of oil and activated sludge, to offer specific solutions in the production of gelatin, promoting the principles of industry 4.0 and environmental sustainability. We are able to provide solutions for different parts of the gelatin production process: from pre-treatment and neutralization to filtration and product recovery.

ITALPROGETTI is also able to provide environmental solutions: from wastewater treatment to effluent recycling.

PRETREATMENT

The process of producing gelatin begins with the pretreatment of the skin, through various alkaline and acid baths, which initiate the hydrolysis and purification of impurities.

During these processes, it is vital to maintain a specific pH to take care of the quality of collagen, and it is also very important to get a high value-added gelatin on the market. In those regards, ITALPROGETTI offers solutions with polypropylene drums that allow total control of the process, maximizing yields and minimizing the use of water and chemicals.

Polypropylene drums

The characteristics of polypropylene drums offer more efficient washings and an important polyfunctionality, since it can be used to carry out the processes of epilation (including oxidative), alkaline treatment, discoloration and acid treatment, without the need to change drums, in addition to this, intermediate and final washes are more efficient due to their mechanical action.

Easy cleaning → water saving
Better control of bath temperature → saving chemicals
Chemical resistance → flexibility of use
Greater internal volume → greater load capacity

Automation and control system

Automated systems for dosing water and chemicals ensure, on the one hand, greater production efficiency and production homogeneity, and, on the other, greater operator safety and reduced margins of error.

To further increase the degree of automation, the entire department can be integrated with Leonardo remote control software.

Thanks to this software, all processes can be run in fully automatic mode whenever possible. Where manual intervention is required, the system provides all necessary guides to the operator.

FILTRATION SYSTEMS

Filter press systems are used in the clarification of liqueurs after the extraction of gelatin: this technology has many advantages as it allows to minimize losses in the filtering medium at the beginning and during the process.

Filter-press

The filter press system developed by ITALPROGETTI, already used in the field of oil filtration and sludge dehydration, offers a precise and effective solution for the clarification of gelatin.

Reverse osmosis

Reverse osmosis is a separation process that uses a semi-permeable membrane to remove impurities from water. In the gelatine industry, this process becomes important when extremely pure water is required, as in the case of extraction, as it guarantees safety and an ion-free environment to optimize the quality of gelatine. Among the advantages of our supply:

Design flexibility and reduced auxiliary equipment costs.
Supply of turnkey projects and ready-to-use pre-assembled units (containerized units also available)
Wide range of pressures and capacities according to customer requirements

ENVIRONMENTAL SOLUTIONS

ITALPROGETTI has extensive experience in wastewater treatment, and are also used in the production of gelatin. Some processes use large quantities of water: the solutions proposed by ITALPROGETTI aim to recover and reuse these waters through separation, filtration and storage processes.

These processes, then combined and automated, allow to save up to 30% of the water used.

ULTRAcell DAF

It is important to recover the fat after the skin treatments for a number of reasons .It is significant from an economic perspective because it enables you to take advantage of the increased value that these recovered fats have on the market. From an environmental perspective, it lessens the amount of fats and oils in the final effluent that needs to be filtered.

Because of this, ITALPROGETTI creates a DAF technology that allows for the recovery of these fats.

Capacity up to 1.500 m³/hr
Filtration degree from 300 μm to 3 mm
Wedgewire stainless steel drum
Complete with solid squeezing
Complete with high pressure washing device (using both cold and hot water)
Suitable also for greasy waters
For heavy duties and high performance applications
Easy operation

Recovery tanks

The wastewater discharged after the second/third washing of the leather, is filtered and stored in silos. This water will be able to be loaded back into the drums for more
intense washings, and then be eventually discharged.

The management of the tanks and the discharge/loading of water into the drums is fully automated by the dosing systems. Overall, the recovery systems guarantee a significant saving of water that would otherwise be discharged.

Depending on the required production levels, these tanks can be replaced by a complete system.