processing lines and equipment for the instant coffee industry

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

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Processing Lines and Equipmentor Instant Coee Powder


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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


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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.


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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


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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.


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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.


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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.


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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]

processing lines and equipment for the instant coffee industry

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