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Animal Gel Preparation
20
Animal Gelatin Preparation
Standard Formulation
Formulation
& Weighing
-40% animal gelatin
-40% water
-20% glycerin
Weigh ingredients using an accurate scale
Formulation Example
If making a 30 kg batch, the formula calls for:
Formulation Example
Gelatin: 30 kg x 0.4 = 12 kg
Water: 30 kg x 0.4 = 12 kg
Glycerin: 30 kg x 0.2 = 6 kg
Heating & Mixing
1. Set gel melter to 75°C
2. Allow melter to reach 75°C
3. Add water & glycerin to melter
4. Add gelatin to melter
5. Close and tighten melter lid
6. Turn on mixer
7. An optional deaeration may be performed at this time. Deaerate for 3-5 minutes and leave tank under vacuum while mixing
8. Mix for 45 minutes
Gel Melter Introduction
Vacuum Valve
- Opened (pictured) before turning on vacuum pump for deaeration
- Closed at all other times
Control Panel
- Used to control:
- Main Melter Power
- Lid Lift & Lower
- Vacuum Pump
- Mixing
- Heating
- Melter Temperature
- Mixer speed (if applicable)
Drain Valve
- Closed (pictured) before adding ingredients to the melter
- Opened to drain out excess gelatin or water after cleaning
Air Pressure Valve &
Relief Valve
Air Pressure Valve
- Opened when transferring gelatin to the encapsulator
- Closed (pictured) at all other times
- Air supply attached to
regulator when transferring gelatin
Pressure & Relief Valves
Relief Valve
- Opened (pictured) before turning on vacuum pump for deaeration
- Used to regulate level of foaming gel mass during deaeration
- Closed when transferring
gelatin to the encapsulator
Transfer Port
Transfer Pipe
- Inserted into transfer port
when transferring gelatin to encapsulator
- Removed during the gel preparation process
- Turning on the mixer with the transfer pipe installed will result in melter damage
Transfer
Port
Transfer Port
- Port shown with transfer pipe removed
- Port is capped during the gel preparation process
Viewing Window
Viewing Window
- Used to monitor melting/deaeration process
- Wiper blade used to clear condensation
- Can be easily removed for sampling gelatin
Viewing Window
Built-in Flashlight
- Illuminates inside melter for clear viewing
Heating & Mixing
Deaeration
1. Ensure the following:
-Relief valve open
-Air pressure valve closed
-Vacuum valve open
2. Turn on mixing
3. Turn on vacuum pump
4. Close relief valve to begin building vacuum
5. Use relief valve to manage foam level
6. Continue until foam settles and no longer rises
7. Turn off vacuum pump & mixing
8. Open relief valve
9. Inspect gelatin
10. Set melter to 60°C for storage
Summary
1. Preheat melter to 75°C
2. Formula: 40% Gelatin, 40% Water, 20% Glycerin
3. Add ingredients to melter
4. Begin mixing
5. (Optional) Initial deaeration: 3-5 minutes
6. Mix: 45 minutes
7. Final deaeration: until foam stops rising
8. Store gel at 60°C