The Small line process with limited automation operations follows proven Coctio principles producing traditional bone broth combined with Chef's cooking technique to generate new revenue streams with a possible payback period of less than one year.
The Small turnkey line is modular, which means that you can add capacity or functionality as you grow. It also allows the production of highly demanding, clean label applications, including soups, sauces and ready meals.
The line installation 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 a minimum 50 m² production space for its smallest line installation.
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. One crucial aspect of high productivity is that you don't need to have supervision while it is cooking, which would allow overnight cooking.
One cooking 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. The batch volume of concentrated broth BRIX 20 or demi-glace is over 800 litres. More capacity can be added by simply adding modules to the oven and cookers.
The amount of bone raw materials to process and product categories that are desired to produce will determine the required process steps and the overall capacity of the Small line eventually to optimally meet your production requirements.
One batch of broth extracts 180 kg of pure animal fat and approximately 1,600 kg of cooked bones residue. In a Coctio process, the fat is purified, kept in liquid form and stored to use it in own food production or can be sold to other industries, such as to the biodiesel industry as an inedible ingredient that will use it to make fuel. The cooked bones can be further processed in-house into new material, such as compost using dedicated equipment found on the market or bones can be sold to other industries for further processing into animal feed and organic fertilizer material.
The diagram below illustrates the Small volume production process and outputs.
Small line is designed especially for:
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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, sauce and other food products.
Free from additives, bone stock can go directly into any application as a clean label and functional ingredient.