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Instant Coffee Processing Technologies

S.Anwar Ahmed , Vice President - Technical

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Why Customised Solutions for Instant Coffee

Processing

• Competitive Market

• Increasing Costs of Energy

• Quality awareness of Customers

• Increasing Costs of Transportation

• Increasing Costs of Man Power

LOGO Where to Optimise ?

• Roasting

• Extraction

• Extract Recovery from Clarified Sludge

• Aroma Recovery

• Extract Concentration

• Spray Drying

• Agglomeration

• Freeze Drying

• Steam Energy Generation

• Optimising Cost Effective Automated

Systems

LOGO Instant Coffee Processing

Green Coffee Cleaning, Roasting

& Grinding

High Pressure

Counter Current Extraction

Extract Clarfication

Aroma Recovery & Evaporation

Spray Drying

Process Steps & Products

Coffee Concentrate

Spray Dried Powder

Agglomerated Granules

Freeze dried Granules

Instant Pre-Mixes

Process Steps Products

Agglomeration

Freezing & Freeze Drying

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LOGO The Beans….

• Coffee Robusta

• Coffee Arabica

– The Roasted Coffee Grounds Yields 34% to 56% of Instant Coffee In

– High Pressure Extraction & 15-22% in Atmospheric Pressure Extraction

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Green Coffee Cleaning, Roasting &

Grinding

Preparation For Extraction

Controlled Grinding to Protect Aroma

Removal of Fluff and Extraneous Matters

Separation of Stones and Grits

Controlled Roasting in Cycles

Process Steps w w w . s s p i n d i a . c o m

LOGO Cleaning & Storage

LOGO Storage & Blending

LOGO Roasting

• Roasting of Green Coffee Beans Can be

done by using Biomass in place of Diesel or

Gas

LOGO Grinding

LOGO High Pressure Counter Current Extraction

Filling Of

Extraction

Cells With

Roasted

Coffee

Grounds

Counter

Current

Extraction

With Hot

Water At 185

Deg C

High Pressure

Hot Water

Generation At

185 Deg C

Inter Cell

Cooling Of

Coffee Extract

Extract Draw

Off And

Cooling

Spent Coffee

Discharge

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LOGO PLC- Extraction System

LOGO Variations In High Pressure Counter Current Extraction

• Wide Body Short Column Single Stage

High Pressure Counter Current

Extraction For High Yield and Highly

Purified Aroma Separation

• Space Economy, High Yield upto 52%

Soluble Solids from Roast Coffee

Grounds

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Wide Body Short Column Single Stage High Pressure

Counter Current Extraction-Type I

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Wide Body Short Column Single Stage High Pressure

Counter Current Extraction-Type II

LOGO Variations In High Pressure Counter Current Extraction

• Wide Body Short Column Two Stage High

Pressure Counter Current Extraction For

High Yield and Highly Purified Aroma

Separation

• Space Economy, High Yield upto 56%

Soluble Solids from Roast Coffee

Grounds

• Energy Savings of upto 10% as

Compared to Single Stage Extraction

LOGO Atmospheric Pressure Extraction

Cont Feeding

Of Counter

Current

Extractor With

Roasted

Coffee

Grounds

Counter

Current

Extraction

With Hot

Water At 90-95

Deg C

Hot Water

Generation At

95 Deg C

Aroma

Condensation

Of Coffee

Extract

Continuous

Extract Draw

Off And

Cooling

Spent Coffee

Discharge

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LOGO Atmospheric Pressure Extraction

• Atmospheric Continuous Extraction With

High Quality Coffee for Cold and Hot

Coffee Beverages With Soothing Aroma

Separation

• Very Low Energy Consumption

• 24/7 Operation

• Highest Quality Aroma

LOGO Atmospheric Counter Current Continuous Extraction -1

LOGO Atmospheric Counter Current Continuous Extraction -2

LOGO Two Stage Continuous Atmospheric Extraction-

LOGO Atmospheric Extraction With Aroma Recovery

LOGO Clarification And Storage

The Clarified Extract Carries 8-13% (Approx). Of Soluble Coffee Solids

in High Pressure Extractionn & 2-8% in Atmospheric Extraction

Extract Holding

& Storage Continuous

Clarification Cooling Of

Coffee Extract

Process Steps

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LOGO PLC –Clarification System

LOGO Continuous Clarification

LOGO Aroma Recovery & Evaporation

Aroma Is Stripped In Bubble Cap/ Rotary Cone Distillation Column And

The Extract will be carried over to Evaporator Calandrias for

Concentration.

Heating Media - Steam

Aroma

Stripping

From Extract

Extract

Concentration

in Multi Effect

Evaporator

Concentrate

Collection &

Cooling

Process Steps

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LOGO PLC- Concentration System

LOGO Aroma Distillation –Standalone

LOGO Aroma Distillation –Standalone

LOGO Integrated ARC & 5 EFF Evaporator

LOGO Extract Concentration

LOGO Spray Drying System

Concentrate

Collection &

Heating

Aroma

Blending CO2 Dosing

Feeding to

Spray Dryer

Through

Automisers

Hot Air

Supply To

Spray Tower

Aroma mixed with

Concentrate

Hot Air at 180 – 220 Deg C will

carry away the moisture from

the automised Coffee Extract

Bulk density of Coffee Powder

can be Controlled with CO2

Dosing

Automised feed will Dry

the Extract Almost

Instantaneously by

protecting the Aroma

Heating reduces the

viscosity of Coffee

Concentrate for better

Spraying

Aroma rich

Spray Dried

Powder Process Steps

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LOGO PLC –Spray Drying ystem

LOGO Spray Dryer Top Head

LOGO Spray Drying System

LOGO Agglomeration System

Pin Mill

Instant Powder required

to be milled to further

fine particles for better

agglomeration

Powder, Steam, Hotair

The Fine powder is

mixed with steam and

Hot air is supplied

simultaneously

Tower Agglomeration

The Steam

Agglomerates the

particles into Granules

and dries with Hotair

Supplied

simultaneously.

Granule size can be

controlled.

Milled Powder Feeding Coffee Agglomeration Instant Coffee Powder Milling

Process Steps w w w . s s p i n d i a . c o m

LOGO PLC – Agglomeration System

LOGO Agglomeration System

LOGO Pre-Freezing, Freezing & Freeze Drying

Foaming with CO2

Pre-Freezing With refrigerant

Continuous Feeding On Conveyor

Freezing With Chilled air Circulation around Conveyor at Different Zones

Frozen in Stages -10 Deg C, -25 Deg C, -45/50 Deg C

Crushed and Milled to Required Size

Ice is Directly sublimes as Vapour

Vacuum condensers removes the frozen vapour by de-frost process

Freeze Dried Coffee Preserves the Aroma very Close to its Natural Flavour

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Foaming & Pre-

Cooling

Maturation &

Pre-Freezing

Aroma Blending Belt Freezing &

Crushing

Freeze Drying &

Vacuum Discharge

Feeding to

Freezing

System

Particle Milling

& Sizing

Packing

Process

LOGO Freeze Drying System

LOGO Freeze Drying System

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Spray Drying, Aggglomeration & Freeze

Drying Plant

LOGO Spray Dried Coffee Process Flow

LOGO Cost Savings Over New Technology Use

• Extraction– Energy reuse ~ 10 %

• Evaporation-- 5 effect ~ 40%

• Spray Drying – Condensate Energy Use -~ 5 %

• Agglomeration - Design ~ 35%

• Freeze Drying – Absorption Refrigeration

~ 35%

• Two Stage Extraction - Design ~ 20%

• Over All ~ 20% -25%

• Using Biomass ( Rice husk, Coffee Husk, Spent

Coffee, Wood Chips etc ~ 50 -60%

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THANK YOU w w w . s s p i n d i a . c o m