Responding globally to our clients needs producing natural bone broth products at smaller volumes while maintaining the finest product quality and low production costs, Coctio offers a Small Production Line with a low initial investment. This line also allows production of highly demanding, clean label applications, including soups, sauces and ready meals.
The Small line with limited automation operations follows Coctio method producing natural bone broth with Chef's cooking technique and flavour expertise. The process is highly reliable, for safe, hygienic quality and easy operation. It allows you to start with low capacity and smaller machine and then lets you increase volumes and more new products as your business grows to meet future demands.
The compact, turnkey line is delivered pre-assembled, which ensures quick and easy installation by Coctio installation team. The line is ready for connection with the pipes to Coctio equipment and the available power supply reducing installation expenses to a minimum. On top of that, the small volume line can be adapted to almost any production facility, making it suitable for both retrofit and new plant installations. It only requires as minimum 50 m² production space for its smallest line installation.
This low-volume manufacturing system is designed especially for:
One batch produces 2,200 litres of natural bone broth which requires 1,800 kg of animal bones and 2,000 litres of water. A daily broth volume can be increased to over 14,000 litres at top production by running the operation with 3 cookers in three shifts without having to increase the operators overseeing to the cooking process. The batch volume of concentrated broth BRIX 20 or demi-glace is ovwr 800 litres.
Also, one batch generates 180 kg of pure fat and approximately 1,600 kg of cooked bone residue. The fat is purified, kept in liquid form and stored to use it in own food production or can be sold as an ingredient to other industries.
The cooked bones can be dried and further processed into dried meat and bone powder in a Coctio Dryer system and sold on the industrial markets.
Small production line’s maximum daily and yearly capacity and projected production in terms of end-product and target market vary according to your demands and the number of cooker modules you have for a Small line.
The diagram below illustrates the Small volume production process and outputs.
Key processes and modules
The process operations and control of roasting the bones, cooking the broth and evaporating it down are run automatically to ensure that the most critical processes are repeated as desired for every single batch of production with the same high quality and characteristics. Control of other processes is done manually. However, the system offers a possibility to automate the whole operation as an option.
Due to critical processes are automated, only a few operators are required at a time to run the operation of the plant.
Expand your business knowledge in profitable low volume bone broth, soup and sauce production industry and learn about its process technology, business opportunities and financials by downloading our free e-Books below!
In this free guide, you'll discover a complete process description of low volume manufacturing of perfect Bone Broths, Soups & Sauces.
Get this free guide to assess revenues, cost structure, financing needs and profits to operate a small-scale bone broth production facility by processing annually over 4 million kilos of animal bones into a range of natural bone broth, soup and sauce products and functional, clean-label friendly food innovations using bone broth as a natural ingredient.