Are you looking to establish a bone waste-processing or bone broth and sauce production plant? Welcome to this multi-part blog focused on a specific Coctio processing line that helps the food processing and animal by-products industry to manage the treatment of bone waste, maximise the yield from bone remains and generate new revenue streams. We are going to tell you how our team manufactures and completes the assembly of the bone broth manufacturing line, and how our customers can quickly take advantage of new business opportunities by turning meat and fish bone waste into high-margin and high-demand products such as additive-free bone broths and sauces.
If you're unsure how the Coctio processing line can work for your business, follow this blog and participate in the progress of the line project during the next four to five months. Feel free to post a question in the comments box below, or contact us to schedule a conversation with us directly.
In the first part of the blog together with Esa Puhakka, our Project Manager, I will share a simple summary of the machines associated with industrial bone broth, soup and sauce preparation, and also describe what operations and installations have been done so far at the Coctio production facilities. The level of equipment readiness mentioned is based on week 3/2016.
PART 1: Summary of the bone broth and sauce preparation process and associated equipment - view progress on the line
1. Loading module (Bones feeder)
The readiness of the loading module, the first piece of equipment in the processing line, is currently 80%. Technically the module is ready to be installed, but the electrical installation and automation are still waiting for final assembly. This can be done when the vibrating feeding table belonging to the module and double screw conveyor are complete.
The loading module folds bone raw materials via the double screw conveyor into the vibrating table, from which they are fed into either the oven or cooker modules, depending on the type of bones and recipe being used.
2. Oven modules
Oven module readiness is 60%. The mechanical installation work such as the installation of the driven roller conveyor is still not complete. Electrification and automation work follows as the next step.
The broth and sauce preparation process requires the bones to be roasted at the right oven temperature and for the correct roasting time according to Coctio recipes.
3. Vibrating Feeding Table
Next in the process, roasted bones are fed through the vibrating feeding table to the transfer pipe.
4. Two Cooker modules
The mechanical completion of the cooker modules is now 98%. Instrumentation, which means the installation of electric cables and pneumatic tubes, has already been initiated in the first cooker module. The readiness of electrical work is 50%. Automation follows the electrical work.
In the cooker, meaty bones are cooked using the classic chefs’ cooking method and recipes of slow simmering. The cooker’s structure and automation have been designed to ensure the consistent quality of the culinary end product. Cookers are ideal for cooking meat, fish, seafood and vegetable broths and soups as well as demi-glace sauces.
5. Cyclonic separation and filtration unit
The filtration unit separates the large particles from the air streams. The readiness is 55%, and automatic installation will be carried out as the next step.
6. VAC Unit
The VAC unit pulls bones from the bone transfer tube into a cooker module. Equipment readiness is 60%, and the unit’s electrical and automation will be carried out next.
- Filtering unit
The filtering unit components are in production and ready for installation. Mechanical construction will begin during week 4/2016.
In a cooking bone broth process, this unit filters the broth and fat separately. Equipment readiness is 25%.
- Product tank
From the filtering unit, the broth is fed into a product tank. From the tank, broth can be recycled back to the cooking process, or can be an intermediate storage for broth before being passed on to the evaporator supply tank. All the necessary components are ready for installation. Equipment readiness is 75%.
- Evaporator Supply Tank
The mechanical structure is similar to that of the product tank as mentioned above. From the supply tank, the broth is fed into an evaporator if sauce bases and demi-glace sauces are in production. In the supply tank, the broth is recycled in accordance with the Coctio recipes. All the necessary components are ready for installation, and its readiness is 75%.
In evaporation, the water is separated from the broth at a rate of 3.5 m³ per hour until the broth structure is as desired. Evaporator readiness is 75% and the electrical and automation installation work will soon be complete.
- Fan Room Container
The fan feeds air at the desired temperature into the evaporator. If necessary, the temperature is increased by feeding the booster steam. Fan room readiness is 35%.
- Finished Product Tank
The finished product tank is the same as the product tank mentioned above. The readiness is 75%.
- CIP Cleaning Centre
Mechanical engineering is currently in progress and followed by automation instrumentation. Its readiness is currently 55%. The Cleaning Centre is optimised to clean all the connected equipment and pipelines for an automation washing line.
The fat separation and bone residue processes with their associated equipment have not yet been written about in this blog. We’ll write about these processes shortly. Stay tuned for post 2 in our series in week 7!