Standard Broth, Soup and Sauce Production Lines

Small Broth, Soup and Sauce Production Lines

Creating natural bone broths, soups and soups at larger volumes

Suitable for large-scale production of bone broths for clean label food applications from valuable animal bones

The large-scale capacity Standard Line for production of natural bone broths, soups and sauces is designed to address the manufacturing of more healthier food products, including clean labels with high commercial value for professional, consumer and industrial markets. The line is designed with large volumes in mind, both capacity in bone raw materials and end products. Production is easy to scale up in capacity depending on your demand, meaning that daily volumes from 4.5 tonnes of natural broth up to 100 tonnes can be achieved. Despite the large capacity potential, the line provides simple and flexible operation due to the high degree of automation achieving consistent top-quality of your food labels. Such scalable production line is highly cost-effective and very efficient to operate. 

Further along the process, the SHS Dryer line allows cooked bone residue drying and processing for dried proteins for use in dry pet foods, and bone powder for use in fertilisers and animal feeds, resulting in zero bone waste.

The 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. The large volume line requires minimum 500 m² production space for its smallest line installation. 

This high volume manufacturing system is designed especially for: 

  • Medium to large businesses in food, meat and fish processing and slaughtering
  • Current bone broth producers improving production rates and operations
  • Rendering plants 
  • Companies and investors who want to establish a highly profitable bone broth production business 

Capacity of the Standard Production Line

One batch produces 4,500 litres of natural bone broth which requires 3,500 kg of animal bones and 4,200 litres of water. The batch volume of concentrated broth or demi-glace is roughly 1,710 litres.

Also, one batch generates 350 kg of fat and approximately 3,150 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 the pure ingredient to other industries to make commercial products. 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. 

Standard 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 Standard line.

Complete production process

The diagram below illustrates the Standard volume production process and outputs.

Coctio Standard line process diagram

Key processes and modules

  • Roasting the ingredients (Oven module) *
  • Broth Cooking (Standard cooker module) 
  • Filtering the Bone broth and the fat (Filtering module)
  • Broth Evaporating (Evaporator module) *
  • Mixing and Cooking Sauces/Soups with/without particles (Sauce & Soup preparation module) *
  • Fat Clarification (Fat Clarification module) 
  • Cleaning of equipment and pipes on the production line (CIP module) 
  • Drying the cooked bone residue (Coctio SHS Dryer module) *
Available add-on modules to your Standard Line setup 

The Standard production line is modular which makes it possible to add process steps and equipment modules to expand the functionality of the line to create more complex products, such as demi-glace, flavoured sauces, soups and other natural ready meals. The versatility of the line set-up makes it possible to adjust the process to the desired operation and help you meet the requirements of your customers
 



Automatic operation 

A simple-to-use, fully automated process control ensures that all operations are repeated as desired for every single batch of bone broth. This allows you to produce large quantities of end-product over a number of batches with the same level of quality and characteristics every time. The automation also allows you to have a very efficient and consistent production line that requires very little supervision.


Main advantage

  1. 100% Natural end-product (natural mouthfeel flavour, structure and clarity)
  2. Turnkey solution for large-scale production with quick profit 
  3. Automated closed system for gentle handling the raw materials and total control of all processes ensuring consistent high-quality of products 
  4. Great flexibility for variations in natural bone broth-based products and clean label applications
  5. Modular design to fit your capacity requirement and can be easily expanded as you grow
  6. Capable of handling particles through sauce and soup preparation process
  7. Process and equipment complies with European safety and hygiene standards


E-Book Tutorials for large 

volume business

Expand your business knowledge in profitable large 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!

eBook: Large Volume Broth, Soup & Sauce Process Overview 

eBook - Standard Line solution for large volume manufacturing of perfect bone broths  

In this free guide, you'll discover a complete process description with equipment specifications for large volume manufacturing of perfect Bone Broths, Soups & Sauces. With it, you will be able to take full advantage of best practices for manufacturing operations of natural and organic bone broths and broth-based ready-made meals.

Get the Coctio Business Case for Small volume Bone Broth, Soup and Sauce production operation

 

eBook: Business Case for Large-Scale Broth, Soup & Sauce production

eBook - Business Case for Large-Scale Broth, Soup and Sauce Production  

Get this free guide to assess revenues, cost structure, financing needs and profits to operate a large-scale bone broth production facility by processing annually over 9 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.

Get the Coctio Business Case for Small volume Bone Broth, Soup and Sauce production operation