EU legislation1 for food safety rules for the processing of animal by-products, i.e., all bone residues from slaughterhouses which are not used for food production must be disposed by rendering. However, current large-scale rendering method has three main fundamental effects of slaughterhouse, food production and farming industries. These are high costs, raw material loss, and unsustainability of processes. Rendering plants are commercial bodies that charge service fees for disposing animal waste. Therefore, rendering fees are by law imposed extra costs for food manufacturers, slaughter industry and animal farming. For example, in 2017 in Finland meat producers had to pay at least 0,18 €/kg for disposal of bone residues.
The market-leading Coctio method is the first comprehensive value-added solution for the food and rendering industries for more efficient and effective animal bone management to improve resource efficiency and sustainable production of bone raw materials into 100% yield and new sources of revenue, leaving zero bone waste.
The Coctio method consists of:
A novelty value in Coctio technology is based on making full use of organic materials in bone residues contrary to contemporary rendering practices. With Coctio's concept slaughter and food industries can make a big difference to their animal bones leftovers process, utilising the bones more efficiently, increase the bones yield and value of bones as raw material, all leading to a boost in your profit margins. Instead of getting rid of the bones at a relatively low price, the Coctio process uses 100% of bone residues to producing value-added products offering a net profit starting from €0,50/kg of bones.
Not only how food is processed, but also simplification and artificial ingredient reduction also play an essential role in supplying clean labels to global food markets. Consumers are becoming more aware of the environmental and healthy aspect of their eating decisions, which has already created new kind of pressure for food processing industry to keep their actions green and labels more natural, healthy and clean. Those food manufacturers that can meet the requirements of the consumers and become sustainable manufacturers will be the ones that prosper financially. Furthermore, the increasing premiumization of indulgence ready meals is one of the significant growth drivers for natural bone broths, flavoured soups and ready sauces. Consumers are willing to pay more for clean label products with high-quality, being more natural as well as offering natural umami taste credentials and health benefits due to the lack of additives and e-numbers included within them.
With Coctio’s technology, more human food, more by-products of high commercial value, less slaughterhouse waste as well as less landfill waste and emissions will be generated compared with existing practices related to animal bones processing.
Coctio process yields three main fractions:
The first fraction produced with a Coctio bone broth production line is natural bone broth and stock. It is manufactured by roasting the broth ingredients, such as crushed bone fractions in size of 4 to 10 cm and vegetables in a Coctio roasting oven module followed by cooking in a Coctio cooker module and by simmering the ingredients for hours according to recipes. Different flavours and natural ingredients will add body, savoury, colour and texture to these culinary products. The cooking process yields tasty and healthy bone broth free of additives for the retail, foodservice and industrial markets as well as an ingredient for moist and semi-moist pet foods. After bone broth preparation, the broth can be evaporated into natural concentrated broth and type of demi-glace, ready sauces and soups.
In addition, and if desired, cooking of bone residues yields considerable amounts of hygroscopic structural protein collagen, extracted from bones and connective tissues by partial hydrolysis, which after separation and drying yields gelatin. Gelatin is a polypeptide much in demand for instance in pharmaceutical and food industries where it is used in an auxiliary and gelling agent, respectively.
The second fraction obtained from our bone broth line is pure animal fat, composed of C16-C18 and other saturated and unsaturated fatty acids. The chemical composition of fat slightly depends on animal species. Animal fat is a valuable ingredient for food, cosmetics and renewable energy industries2.
The third main fraction obtained from the bone broth line is hot water insoluble material composed of residual bone, meat and other animal tissues. The material can be dried by using our SHS Drying technology to separate meat residues from other tissues to produce pet food protein.
The final part of the transforming process is to utilise the residue to produce renewable energy and organic fertilisers from milled bones. When used as fuel, the energy value of dried and milled bone grain equals to that of wood chips also, a mixture of bone meal and wood chips will burn cleanly in an ordinary combustion furnace. The ash of bone meal contains considerable amounts of elements, such as phosphorus, calcium and trace elements and therefore it is an ideal organic fertiliser, too3.
The table below indicates expected yield and value of products obtained using a Coctio Standard bone broth production line for large-scale production with a capacity of processing yearly 10 million kg of bone residues. The aggregate potential value of products made from 10 million kg of bone residues exceeds 40 M€.
|PRODUCT||QUANTITY / YEAR||UNIT PRICE||MARKET VALUE, M€/YEAR|
|Bone broth||12 million litres||2,25 €/litre||27|
|High quality gelatin||200 000 kg dw||10 €/kg||2|
|Concentrated broth||1,2 million litres||5 €/litre||6|
|Fat||1 million kg||0,50 €/kg||0,5|
|Pet food protein||0,8 million kg dw||5 €/kg||4|
|Fuel||5 million kg dw = 26,5 TWh*||5 snt/kWh||1,3|
|Fertilizer||5 million kg dw||0,18 €/kg||0,9|
|TOTAL||40,4 - 40,8|
* heating value = 5,3 kWh/kg, dw = dry weight.
Explore and identify opportunities to increase sales and grow your business with large volume bone broth manufacturing and the value of a Standard line investment by downloading our business case.
1 Regulation (EC) No 1774/2002
2 Banković-Ilić, I.B., Stojković, I.J., Stamenković, O.S., Veljkovic, V.B., and Hung, Yung-Tse. Waste animal fats as feedstocks for biodiesel production, Renewable and Sustainable Energy Reviews 32 (2014) 238–254
3 Jeng, A.S., Haraldsen, T.K., Grønlund, A., Pedersen, P.A. (2007) Meat and bone meal as nitrogen and phosphorus fertilizer to cereals and rye grass. In: Bationo A., Waswa B., Kihara J., Kimetu J. (eds) Advances in Integrated Soil Fertility Management in sub-Saharan Africa: Challenges and Opportunities. Springer, Dordrecht