Precision in Every Step, Purity in Every Granule
At Sterling Gelatin, our manufacturing process is built on precision, purity, and decades of industry expertise. Using carefully selected raw materials and stringent quality controls, we convert collagen-rich ossein into pharmaceutical, nutraceutical, and food-grade gelatin of unmatched consistency and performance.
1. Raw Material Selection
The journey begins with the procurement of crushed buffalo bones from certified suppliers. These bones are a rich source of collagen and serve as the primary raw material for gelatin production.
2. Acidulation
The crushed bones are treated with dilute hydrochloric acid in acidulation vats. This process removes calcium and phosphate, resulting in a demineralized collagen matrix known as Ossein.
3. Liming
The Ossein is soaked in calcium hydroxide (lime) for a minimum of 20 days. This crucial step softens the collagen and initiates partial hydrolysis, preparing it for efficient extraction.
4. Washing & Neutralization
After liming, the Ossein is thoroughly washed to remove excess lime. A mineral acid is then added to adjust and stabilize the pH, ensuring ideal conditions for gelatin extraction.
5. Extraction
The prepared Ossein is pumped into extraction pans, where gelatin is extracted in a series of temperature-controlled stages. This process helps isolate high-quality gelatin without compromising its structure or functionality.
6. Filtration, Deionization & Concentration
The gelatin solution undergoes fine filtration and deionization to remove impurities. It is then concentrated to 30% solids under vacuum conditions, ensuring both clarity and purity.
7. Sterilization & Solidification
The concentrated gelatin is sterilized using a Direct Steam Injector (DSI) and solidified through a votator system, forming gelatin noodles ready for drying.
8. Drying & Final Processing
The noodles pass through an 8-zone tunnel dryer, gradually reducing moisture content while preserving quality. The dried gelatin is then crushed and blended into various grades to meet specific customer requirements.
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