processing lines and equipment for the instant coffee industry

Upload: ouerdien

Post on 08-Apr-2018

219 views

Category:

Documents


0 download

TRANSCRIPT

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    1/8

    Processing Lines and Equipmentor Instant Coee Powder

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    2/8

    Everyone appreciates the convenience o

    using a spoonul o instant coee to makean enjoyable cup o coee. Behind the

    convenience, however, lies the challenge to

    the beverage industry o processing the coee

    bean types (Arabica, Robusta) to deliver aroma

    and avour in the cup that appeals to the

    consumer.

    At Anhydro we know all about the important

    role each instant coee processing stage

    plays in creating the fnal product properties

    that ensure coee drinking pleasure. Our

    coee policy is about basing our instant

    coee processing lines on our own specialized

    liquid concentration and powder processing

    technologies while, collaborating closely

    with independent company members o

    the Anhydro Coee Processing Technology

    Alliance (ACPTA) who specialize in other

    essential aspects o instant coee processing.

    Our coee policy and oerings

    This means that we can leverage our

    international contract management andengineering experience going back over 60

    years to oer our customers ully engineered

    instant coee processing solutions that employ

    the latest technology to ensure the right end-

    product specifcations and consumer appeal at

    the lowest possible total cost.

    Our oerings include the design, engineering

    and supply o processing lines with capacities o

    150, 250 or 500 kg/h o instant coee powder

    (see the table below or urther details).

    In addition, we undertake modernization,

    capacity upgrading and retroftting o existing

    processing lines as well as the supply o

    individual equipment items. This includes

    auxiliary equipment (or steam raising/water

    treatment, stand-by power generation, tote bin

    powder storage, product laboratory analysis

    etc.).

    Capacity and Yield Data

    Instant coffee powder capacity (kg/h) 150 250 500

    at 3% H2O

    Annual production (t/h), based on 7,920 1250 2000 4000

    annual production hours

    Corresponding green coee at 12% residual 345 - 360 550 - 575 1100 - 1150

    moisture requirement* (kg/h)

    Corresponding roasted and ground coee at 290 - 300 460 - 480 920 - 965

    6%residual moisture requirement (kg/h)

    Extraction yield based on roasted and ground 53 - 55 53 - 55 53 - 55

    coee, based on Robusta (%)*Assuming 16% roasting loss

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    3/8

    Coee powder overview

    The drying stage in the processing line is selected according to the desired end-

    product properties and morphology o the instant coee powder. The three main

    types o powder are as ollows:

    Non-agglomerated Instant Coee Powder

    This type o powder consists o individual spherical bead-like particles

    giving the powder its ree-owability and good solubility in hot water.

    It is most economically produced in spray dryers with tower drying

    chambers. Powder bulk density is adjusted through inert gas injection

    into the concentrated coee extract prior to high pressure atomization.

    Agglomerated Instant Coee Powder

    This type o powder consists o either medium-sized or large agglome-

    rates with a minimum o small particles (fnes) present, giving the powder

    superior ree-owability and solubility in hot and cold water. Medium-

    sized agglomerates are most economically produced in spray bed dryers

    incorporating uid bed agglomeration within the drying chamber. Large

    agglomerates are best produced in a dedicated powder agglomerator

    where spray dried instant coee is rewetted and dried under strictly con-

    trolled conditions.

    Granulated Instant Coee Powder

    This type o powder consists o large granules and the absence o fne

    particles gives the powder excellent ree-owability and solubility in hot

    water. It is most economically produced in reeze dryers where the low

    temperature drying environment maximizes aroma retention. The size

    o the granules is determined by the degree o size reduction and size

    classifcation applied to the rozen extract.

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    4/8

    Equipment requirements

    Processing lines to produce coee powders

    comprise various stages involving dierent

    technologies within solids, liquid and powder

    handling. Equipment requirements in these

    stages are as ollows:

    Coee Bean Handling

    Coee Bean Cleaning Equipment

    and Storage Silos*

    Coee Bean Roasters*

    Coee Bean Grinders*

    Coee Extraction

    Liquid-Solids Extractors

    (Percolator Battery Columns

    incorporating the high-yield dual-

    dual extraction mode or achieving

    premium coee extract quality)*

    Coee Extract Handling

    Extract Cleaning / Clarication

    (Filters / Decanter-Centriuges)*Aroma Recovery

    (Flash Separation,

    Distillation / Stripping Columns)**

    O-favour Removal*

    Extract Concentrators

    (Falling Film / Plate

    Evaporators, Parafash)**

    Concentrate-Recovered Aroma

    In-line Mixing (Non-Foaming)**

    * Equipment designed and supplied by members o the

    Anhydro Coee Processing Technology Alliance (ACPTA).

    ** Equipment designed and supplied by Anhydro.

    Applying Anhydro extract preparation techno-logy enables customers to beneft rom:

    High Yield Perormance

    (53 - 55 % o R&G Coee, depending on

    the coee bean type, quality and blend)

    Flexible design permitting dual-dual and

    dual-split continuous operation

    Intermediate cooling o the aroma-rich

    raction during extraction to promote

    aroma retention

    Linear percolator extractor arrangement

    Ease o capacity increase by installing

    additional percolators in-line

    Integrated aroma recovery system

    Integrated system or removal o

    undesired o-avours

    Thermal extract concentration under

    gentle conditions to promote aroma

    retention

    Reuse o the condensate rom extract

    concentration or CIP cleaning and

    percolator cooling, promoting highly

    efcient water usage

    PLC / PC Process Control

    Process stages involved in the productiono spray and reeze dried coee powders

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    5/8

    Spent Grounds HandlingMechanical De-watering Screw Press**

    Coee Extract Drying Freeze Dryers*

    Spray Dryers**

    Spray Bed Dryers**Coee Powder Agglomerators*

    Powder PackingPacking lines or tins, jars,

    bags or sachets*

    Integrated PlantPLC Control System

    Project Management

    by Anhydro

    * Equipment designed and supplied by members o the

    Anhydro Coee Processing Technology Alliance (ACPTA).

    ** Equipment designed and supplied by Anhydro.

    Anhydro drying technology enables customers

    to beneft rom precise control o important

    soluble powder properties:

    Colour (brightness) o the fnal soluble

    coee powder

    Particle size distribution and powder

    structure / morphology

    Bulk density

    Residual moisture content

    Aroma retention

    Flowability

    Solubility

    Mechanical stability

    The latest technology includes Anhydros spray

    dryer air disperser and drying chamber designs

    that enable production o powder having the

    desired particle morphology and taste through

    enhanced retention o desirable aromatic

    volatiles.

    The Anhydro extract concentrate gas injection

    and dosing unit installed on the high pressure

    side o the spray dryer eed line represents the

    latest design concept in the important area o

    powder bulk density control and coee powder

    brightness.

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    6/8

    Schematic diagram o a Falling Film Evaporator

    with fnisher or high extract concentration.

    Green coee bean handlingand extraction

    The initial handling o green coee beans

    involves the removal o oreign matter

    ollowed by bean roasting and grinding.

    Both operations are determined by the bean

    blend and the desired degree o roast. Thepreparation o a concentrated coee extract

    rom the roast and ground coee beans is

    perormed in a series o high-yield percolator

    battery columns operating continuously under

    the so-called dual-dual extraction mode to

    obtain the highest yields. This provides a

    primary extract raction rich in aroma, and a

    secondary hydrolyzed extract raction. The

    high-quality aromas in the primary extraction

    are recovered by ash separation ollowed

    by immediate condensing and storage under

    chilled conditions.

    The process rom coee bean to powder

    The coee bean type and the bean blend composition, together with the processing

    conditions, determine the taste and aroma characteristics o the fnal coeepowder.

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    7/8

    Coee extract treatment andspent grounds handling

    Preparing the extract or drying requires a

    cleaning operation to remove remaining coee

    grounds by fltration or decanter-centriuging,

    ollowed by extract concentration. This

    concentration is obtained in a alling flmtubular evaporator under vacuum at low

    temperature or gentle extract handling. A

    fnisher evaporator must be installed ater

    the main evaporator in order to obtain coee

    extracts with a solids content o 55-60% DM.

    As the aroma is removed rom the coee extract

    prior to concentration, the vapour condensate

    ormed during evaporation is very pure and

    ree o colour and odour. This condensate can

    be reused as washing liquid in the Cleaning-in-

    Place system o the processing plant.

    The concentrated extract rom the evaporator

    is mixed in-line with the liquid aroma raction

    to orm an aroma-rich eed or the subsequent

    drying stage. Extract concentration is essential

    or achieving good product quality and easibi-

    lity in the drying stage.

    The extraction process results in waste product

    consisting o substantial amounts o wet

    spent coee grounds. These grounds can be

    mechanically dewatered to reduce the moisturecontent, enabling their use as a bio-uel in the

    plant steam generation boilers, and resulting in

    a considerable reduction in uel costs.

    Coee extract drying

    The method o drying depends upon the

    required powder properties. Spray drying is the

    most widely used, producing either agglome-

    rated or non-agglomerated coee powders.

    The spray dryer design and operating conditions

    determine the type o powder that can be

    produced. Freeze drying produces a larger

    particulate in granular orm. Granules are

    generally associated with the premium quality

    o powder, but spray drying can also produce

    top quality powders in terms o avour, aroma

    and colour when produced rom the best

    quality green beans.

    Spray drying eatures the spraying (atomization)

    o concentrated extract into hot drying air. The

    spray droplets dry to orm a non-agglomerated,

    ree-owing powder consisting o large

    individual spherical bead-shaped particles. An

    agglomerated powder with low fnes content

    can be produced by combining spray drying

    with powder uidization in an integrated uid

    bed built into the spray drying cone base (the

    spray bed drying concept).

    Powders consisting o very large agglomerates

    are produced in a separate agglomeration

    process in which spray dried powder is rewetted

    by steam, agglomerated, and dried using

    uidization and cascading powder principles.

    Freeze drying includes pre-reezing, oaming

    and reezing o the concentrated extract

    ollowed by granulation - sieving o the rozen

    granules, which are dried in trays (batchprocessing) or on a moving conveyer belt

    (continuous processing).

    On reezing, the water in the concentrated

    extract orms ice crystals, which sublime under

    the inuence o vacuum and applied heat to

    leave a dry granular product. Sublimation is the

    direct phase transition rom solid state (ice) to

    gas phase (vapour). The conveyer belt permits

    much shorter drying times, promoting improved

    aroma retention as the coee granules are

    exposed, only or a relatively short time, to thevacuum conditions inside the reeze drying

    sublimation chamber.

  • 8/6/2019 Processing Lines and Equipment for the Instant Coffee Industry

    8/8

    08.

    08

    L-15-eng

    Anhydro provides a ull range o evaporation

    and drying equipment or the global dairy,

    ood and beverage, industrial, healthcare,

    pharmaceutical, and starch and ethanol indu-

    stries. Focusing on exibility and attentiveness

    to individual customer needs, Anhydro enables

    excellence at every point along the value chain

    as part o our commitment to our customers

    success.

    Anhydro acts as a strategic development

    partner or leading manuacturers all overthe world. Through close collaboration

    with our customers, Anhydro promotes the

    development o innovative concepts and

    optimization o existing processes, enabling

    customers to introduce new products into the

    market as quickly and as cost eectively as

    possible.

    Anhydro A/S

    7 OestmarkenDK-2860 Soeborg

    Copenhagen, Denmark

    Tel: +45 7027 8222Fax: +45 7027 8223

    [email protected]