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.

The bone broth production are using the chicken bone, fish bone, pig bone or beef bone as raw materials, after the bones washing, crushing, bone broth extracting, cooking, broth and oil separating, broth concentrating, blending, sterilizing and filling process to make into the bone broth products.

The bone broth processing machines involve bone crushing machine, bone extracting and boiling tank, bone broth static separating 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 processing line capacity is from 500kg/h-5000kg/h, 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.

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 washing and sorting, 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, and the bone residue will be discharged from bottom of the extraction tank, and bone broth will be pumped to the standing tank and disc separator to separate the solids 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 bone broth will be sent to 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 30-40℃ and discharged.

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.

The bone broth oil treatment system mainly includes a bone broth standing tank to layering of broth and oil, disc centrifuging separating machine to separate oil and broth, a coarse oil tank for oil buffering and storage, tubular separator to refine oil.

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.

Mixing equipment is the soul of condiments and is mainly used for mixing and dispensing of various condiments. This equipment includes mixers, metering pumps, pipe mixers, homogenizers, etc. Through precise measurement and mixing, bone broth products of various flavors can be prepared to meet the diverse needs of the market. When for mixing and blending, due to its high temperature, it also has the pasteurization function.

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.