Bone Broth Production Plant

Bone broth contains a certain amount of protein, collagen, fat, vitamin C, vitamin A, vitamin D, as well as calcium, iron, zinc, phosphorus and other ingredients. It also contains glutamic acid, tryptophan, leucine and other nutrients. Amino acids, therefore, can supplement the body with nutrients and energy needed by the body after ingestion, which has certain benefits for physical health. So it is widely used in various food processing enterprises, such as instant noodles, condiments, meat products, etc., to provide them with high-quality bone broth raw materials.

Bone broth is made from chicken, fish, pork, or beef bones. The production process includes bone washing, crushing, broth extraction, cooking, oil and broth separation, concentration, flavor blending, sterilization, and filling, resulting in high-quality, nutritious bone broth products.

The bone broth processing machines involve bone crushing machine, bone extracting and boiling tank, bone broth settling tank, bone broth and oil separating machine, concentrating system, bone broth homogenizer, bone broth blending and pasteurizing system, bone broth spray dryer, filling system , hot water generating system, and CIP system.

The equipment of the bone broth production line needs to be selected and configured according to specific production needs. Through reasonable process flow and equipment matching, efficient and high-quality bone broth extraction and concentration can be achieved, providing consumers with healthy and delicious bone broth products.

The bone broth extraction adopts to high temperature and high-pressure cooking technology, which has a yield rate 30% higher than that of traditional atmospheric pressure extraction; the soup adopts quantitative mixing technology, and the product quality is stable and uniform; The whole process are equipped with heat recovery technology to recycle the temperature of the production process and recycle the condensed water generated by steam, thus reducing the discharge of sewage and the comprehensive utilization of water.

The bone broth processing line capacity is from 5000kg/day to 50000 kg/day, and the end products can be produced into clear bone broth, concentrated bone broth, bone broth powder and bone broth oil products, and the end products are usually filled into cartons, pouches, bottles or glass jars.

Clear fat-free bone broth: It refers to the fresh bone broth after separating oil and fat to get the fat-free broth products. The end products can be filled into cartons, bottles, or jars.  

Full-fat bone broth: It refers to full-fat broth products, after broth extracting, solid separation, and broth evaporation to get the fatty broth products.

RTD bone broth: It is a high-protein drink made by cooking and extracting animal bones (usually chicken, beef or pork bones) for a long time to extract nutrients such as collagen, amino acids and minerals. It is then UHT sterilized or pasteurized and filled into bottles, Tetra Pak cartons and other containers.

Bone broth oil: It is a by-product of the clear bone broth production plant, the oil after separating from the broth, then refined to get the fine oil products.

Bone broth powder: it refers to bone broth after extracting, cooking, and evaporating, then the bone soup products will be dried into powder with the spray dryer, and the end products can be filled into plastic bottles.

The fresh beef, chicken, pig or fish bones after pre-thawing, then transferring to the bone crusher to ground the bones into small pieces, then the small bones are lifted to the extracting and cooking tank, in the extracting tank, the bone flavor and nutrition is extracted by hot water cooking with about 120-130℃, and the bone residue will be discharged from bottom of the extraction tank, and bone broth will be cooled down to 55℃ by tubular cooler and pumped to the standing tank and disc separator to separate the solids and oil in the bone broth, based on customers’ requirements to produce the clear broth or concentrated broth, the broth oil treatment can be equipped. After that, the clear bone broth will be pumped to an evaporator to concentrate the broth to 55% solid content, then the concentrated broth after blending with the flavor, then spray dried into powder or directly filled into consumable containers such as bottles, cartons or glass jars.

Raw material processing equipment is mainly used for cleaning, cutting and crushing bones. These equipment include bone cleaning machines, bone cutting machines, bone crushers, etc. These devices can effectively process bones into appropriate sizes to facilitate subsequent processing. If the raw material is frozen bone, there is no need for cleaning and sorting, and it can be directly fed into the bone crusher for crushing.

Bone broth extracting and cooking tanks are the core part of the bone broth production plant, mainly including cooking tanks and heating systems. Extraction and cooking tanks usually use pressure extraction tanks, which are made of stainless steel and have good corrosion resistance and thermal conductivity. The heating system uses steam or electric heating to ensure that the bone broth can be heated evenly during the cooking process, fully extracting the nutrients of the bones and effectively separating the bone broth and bone residue.

During the extraction and cooking process, the bone broth will be heated to 120-130℃ by steam and holding for 2-3 hours, after that, the flavor and nutrition will be fully extracted, then cooled down the broth to 50-60℃ by a tubular cooler and discharged to the settling tank for oil and broth separation.

The extraction process is divided into 2 stages, the first stage is bone and water ratio is 1:1.4 feeding into the extraction tank for 2 hours of extraction, the second extraction process for bone and water ratio is 1:1 for 2 hour extraction. One batch of material from bone materials feed into the extraction tank and bone broth discharge from the extraction tank takes about 6 hours, the whole process include material feeding, heating, extraction, cooling and discharging.

This cooking tank is a pressure vessel, with  three-layer jacketed tank, coil jacket, top elliptical head, bottom conical head, low chlorine aluminum silicate rock wool insulation, top center stirring device (variable frequency motor, speed 11^25r/ min), The tank bottom has a large opening lid structure for bone residue discharge, a cylinder opening and closing, a temperature sensor interface on the side of the tank, and a high and low capacitance level gauge interface, equipped with automatic feed hopper and automatic feed valve, and the extraction cooking tanks have the following features:

• The maximum temperature resistance can reach 156℃, and the jacket pressure resistance is 4.5bar;
• It is equipped with a fully automatic emptying device to ensure the complete emptying of the condensed gas;
• It has a reliable safety interlocking device, which automatically locks the bottom cover and the top cover when the pressure is not 0;
• It is equipped with a constant pressure discharge system to ensure that there is no emulsification during the discharge process;
• It is equipped with steam direct injection and two-stage hollow jacket heating, and the heating speed is fast!

The bone broth separation system mainly consists of settling tanks and three three-phase centrifuge separators. Its primary function is to efficiently separate oil, bone solids, and liquid bone broth, ensuring high product clarity and stable downstream processing.

The settling tank is made of SUS304 stainless steel and is designed as a three-layer jacketed insulated tank. It is equipped with a half-pipe coil jacket, with steam heating applied to the jacket. Thermal insulation is provided by rock wool insulation covering both the cylindrical body and the bottom of the tank.

The tank features a 15° conical top head and a 45° conical bottom head. The jacket is equipped with steam inlet and outlet connections. The tank top includes a CIP cleaning port and a feed inlet. The tank is also fitted with a manhole, access ladder, sight glass with light, breather valve, side nameplate, digital temperature indicator, temperature sensor nozzle, conical bottom glass sight window, and three bottom discharge outlets.

The tank is supported by legs equipped with load cells for weighing measurement. A top-mounted central paddle agitator is installed. The upper section of the tank body is fitted with four turbulence (baffle) plates. The agitator is driven by an SEW gear motor, with motor protection class IP55, motor energy efficiency class IE4, and variable frequency drive (VFD) control for soft start and speed regulation.

The separator is SUS304, three-phase separation of oil, soup, and residue; processing material: bone broth; equipped with a stainless steel control cabinet (touchscreen control), variable frequency start; motor protection rating: IP55; motor efficiency class: IE4.

The bone broth oil treatment system mainly includes a bone oil coarse oil tank, a refined oil tank and tubular separators. a coarse oil tank for oil buffering and storage, tubular separators to refine oil.

The bone oil coarse and refine oil tanks are SUS304, three-layer jacketed tank, vacuum vessel; internal pressure: -0.098 MPa; semicircular jacket, jacket pressure ≤ 0.4 MPa; top-mounted eccentric paddle agitator; agitator speed: 60 rpm, variable frequency drive; mechanical seal; SEW geared motor.

The tubular separator is SUS304, three-phase separation; equipped with a removable drum stand and a feeding peristaltic pump; motor protection rating: IP55; motor efficiency class: IE4.

Bone broth concentration uses a forced circulation evaporator to concentrate the solid content in bone broth to about 55%. It mainly includes evaporators and vacuum concentration equipment. The evaporator uses the principle of high-temperature heat exchange evaporation to evaporate the water in the bone broth, while the vacuum concentration equipment uses vacuum conditions to reduce the boiling point of the bone broth, achieve low-temperature concentration, and retain the nutrients and taste of the bone broth.

The bone broth enters the heater after pretreatment, and the water is evaporated under high temperature and pressure, while the nutrients and flavor substances in the bone broth are retained. The evaporated water vapor is condensed by the condenser and then discharged, while the concentrated bone broth is transported to the storage tank through a pump.

Our mixing tanks are designed for blending flavors and salt into concentrated bone broth. The broth is heated to 120°C in the blending tank, triggering the Maillard reaction to enhance flavor, develop rich color, and create a savory aroma in the final product.

High-quality three-layer insulated tank with rock wool, semicircular coil jacket, and top-bottom elliptical heads. Equipped with wall-scraping agitator (30 rpm), bottom shear head (2900 rpm), SEW & ABB motors (IP55, IE4), variable frequency drive, and cooling water solenoid valve. Features mirror-polished inner wall, pressure manhole with sight glass, CIP ports, temperature sensor, sampling port, and weighing module. Pressure rating: -0.98 bar to 0.98 bar. Ideal for bone broth mixing, heating, cooling, and high-efficiency processing.

The filling equipment is mainly used to fill seasoned bone broth into packaging containers. These equipment include automatic filling machines, sealing machines, labeling machines, etc. The filling machine can be adjusted according to different packaging container specifications to ensure accurate filling; the sealing machine can seal the filled containers to ensure the hygiene and safety of the product; the labeling machine can accurately attach product labels to the on the packaging container for easy identification by consumers.

Our CIP (Clean-In-Place) system ensures efficient, automated cleaning of bone broth tanks, pipelines, and processing equipment without disassembly. Designed for food-grade hygiene, it removes residues, prevents contamination, and maintains consistent product quality.