Co-Production Process Of Organic Calcium, Collagen And Collagen Polypeptide From Fish Scale And Plant Design

China produced and consumed large amounts of aquatic products in the world,the amount of processing aquatic products is over19.8million tons in2011.There was more than650thousand tons of fish scale products every year, which is one of the main by-product in aquatic processing.Protein (more than80%is collagen) accounts for about50%to70%in fish scale, and the ash for about20%to50%. Fish scale can be converted into organic calcium, collagen or collagen peptide, that will improve its economic value largly. The object of this study was to compare and explore an effective method to produce organic calcium, collagen and collagen peptides from three different scale sources,such as sardine,grass carp and silver carp,by deliming with organic acid, solubiling with enzyme in low temperature and hydrolying with enzyme in high temperature treatment.The co-production process,HACCP system and plant were established and studied in order to provide the basis for fish collagen industrial production. The main research contents and results were as follows:(1)The decalcifying process and parameters of fish scale was compared and studied. The effect of decalcifying with citric acid and ultrasonic-assisted decalcifying was studied. However, the effect of acid concentration, time of decalcifying, solid-liquid ratio and stirring rat were significant. The decalcifying process was10%of citric acid concentration,6h of decalcifying time,1:15of solid-liquid ratio and150r/min of stirring speed, and that was citric acid concentration of6%,3h of decalcifying time, solid-liquid ratio of1:20in ultrasonic-assisted decalcifying process.The ash content was0.61%and0.13%, respectively.(2)The extraction process and parameters of collagen were studied. The influence of0.5mol/L acetic acid,1%citric acid, ultrasonic, microwave treatment on collagen extraction rate was studied. Ultrasonic treatment during the extraction process can improve the extraction efficiency. Ultrasonic power, solid-liquid ratio, time of extraction and pepsin dosage had significant effect on the extraction rate, the optimum extraction conditions was to use180w ultrasonic irradiation under solid-liquid ratiol:20for8h, enzyme dosage was2000U/gpro, as the extraction rate could reach54.79%.(3)The extraction process and parameters of collagen peptide were compared and studied. The pretreatment could improve the extraction rate taht ultrasonic treatment had a higher rate. The protease could influence the extraction rate significantly.Pepsin had the highest extraction rate in the six type of proteases.Temperature, initial pH, substrate concentration and dose of enzyme all had significant effect on the extraction rate of collagen peptide (p<0.05).The optimal process was with5%substrate concentration and280u/gpro pepsin at65℃for120min, initial pH was2.Under this condition, the extraction rate could reach85.96%.(4)The influence of material properties on the product quality was studied. There was a great impact of scale types,storage, crushing, degreasing and reducing bacteria on production processes and product quality of collagen. There was significant differences in content of ash and collagen between different types of fish scale that silver carp fish scale had a highest content of collagen, followed by grass carp,and sardines scales the lowest, while the ash content was of the opposite trend. Processing characteristics after storage was decreased. NaOH and saturated lime water treatment had a better degreased effect while ozone water and hydrogen peroxide pre-treatment could better reduce the bacterial content of the termined product, and the spray dried product which was extracted from the scale treated by hydrogen peroxide had a whiter color.(5)The establishment of co-production process was started and plant that annual processed1000tons scale was designed. On the basis of comparing and studying the process of degreasing on scales and extraction of collagen, collagen polypeptide. The co-production process of organic calcium, collagen, collagen polypeptides from scale was established, which use ultrasound-assisted organic decalcifying to produce calcium citrate first, then solubilized and extracted collagen by pepsin, and finally produced collagen peptides with enzymohydrolysis in a high temperature. A co-production process line which process1,000tons of scale annually was designed.