Processing

High Yield Coffee Extraction Technology

Figure 1: SPX e&e Coffee evaporation plant

The production of instant (soluble) cof- Finely ground coffee results in a more risk of filter blockage. The SPX high
fee involves many process steps. Since efficient extraction process. If, however, yield extraction system provides a total
the procurement of green coffee beans the grounds are too fine, the resulting of twelve percolators configured in two
is the main direct production cost, the pressure drop over the percolators be- rows of six (Figure 2) These specially-
quantity of beans required to produce comes too high and there is a significant designed percolators have cylinders
one weight unit of end-product is a key
cost factor. The latest coffee extraction
technology from SPX has been shown
to give the potential to use fewer green
coffee beans compared to conventional
extraction technology, offering substan-
tial savings in production costs.

Instant coffee production

process
When the green coffee beans are deliv-
ered to the coffee plant, the beans are
cleaned and stored. When required,
the blended coffee beans are roasted
and ground to the correct particle size
range needed for extraction. A fully
automated filling system is then used to
charge the extractor / percolator under
a slight vacuum. Figure 2: Instant coffee processing line for premium quality coffee

24 food Marketing & Technology • June 2013


which are wider and shorter than a
conventional percolator design, which
enables more finely ground coffee to be
used while limiting the pressure drop
created, resulting in better extraction
capability and premium aroma qual-
ity. Specially designed top and bottom
filters on the percolator further enable
extended running times and minimize
the risk of filter blockage.
Prior to commencement of the actual
extraction process with water, the cof-
fee within each percolator is steam
stripped to recover the desirable and
most volatile aroma compounds. The
resulting steam is condensed and
stored under chilled conditions. For
premium coffee extract quality, an
initial low temperature, lenient extrac-
tion phase is then initiated to obtain
food Marketing & Technology • June 2013
an aroma-rich extract. A second stage
then uses high temperature to produce
high yield, hydrolysed extract. Unde-
sired tastes, or ‘off-flavors’, formed in
the secondary extract by hydrolyzation
are effectively removed by a flash sep-
aration process in a vacuum vessel to
further improve coffee extract quality.
The aroma from the low temperature
aroma-rich extract is recovered,
condensed and stored under chilled
conditions along with the aroma
recovered by steam stripping. The
secondary hydrolyzed extract is
cleaned in a high-efficiency centrifuge
to remove non-soluble solids / sedi-
ments and then concentrated in either
a multi-effect falling-film or plate heat
evaporator. The recovered aromas
are then mixed with the concentrated
Processing
coffee extract from the evaporator to
the desired aroma quality and solid
content. Due to the high viscosity of
the concentrated coffee extract, in-
line mixing with the aroma extract is
recommended to ensure good mixing
with uniform concentration.
To produce the final instant coffee the
extract is either spray dried or freeze
dried. Spray dryers are used to pro-
duce an end-product in powder form
with good soluble properties, whereas
freeze dryers produce an end-product
in granular form with a low fine par-
ticulate content. Both dryer designs
enable the instant coffee manufac-
turer to control essential end-product
properties i. e. bulk density, residual
moisture content, powder morphology
and color.
Key No. 81067
25
Processing
Figure 2: SPX e&e Coffee percolators
When using a freeze dryer an initial pre-
freezing and foaming stage is utilized to
cool the coffee extract down to the point
where ice crystals start to form. A dos-
ing system then adds CO2 or nitrogen
gas for gasification for bulk density and
color control (the release of the inert gas
when hot water is added to the instant
coffee results in a slight foaming on the
surface). The gasified extract is sprayed
onto a moving freezing belt and, once
completely solid, passes through mill-
ing and classification stages. Granules
within the desired size range are loaded
into the freeze dryer where sublima-
tion occurs. Once dried, they are then
discharged for packing.
SPX has a proven track record in provid-
ing turnkey instant coffee plants, which
are designed for optimized energy con-
sumption, higher yield and premium
quality end-product. A programme of
continued technology development and
innovation has led to the unique solu-
tions described above which offer better
aroma recovery and higher yields than
conventional systems while producing
premium, aroma-rich instant coffee
results. Indeed, innovative SPX instant
coffee processing technology modern-
izes conventional production tech-
niques, which were developed during
the 1980s and early 1990s.
Overall, SPX technology and coffee
processing equipment provides instant
coffee producers the potential for:
• Increased aroma recovery and better
sensory end-product
• Increased production and end-prod-
uct quality flexibility
• High yield performance
• A premium aroma-rich instant coffee
end-product
• Reduced off-flavors within the instant
coffee extract
Key No. 81610
26
Advantages of the SPX high yield solution
SPX’s instant coffee processing plants are customized to meet specific end-
product requirements and offer a range of benefits and flexibility throughout
the processing line.
• Steam stripping of aromas prior to water extraction recovers the best and
most desirable aromas from the roast and ground coffee.
• The short and wide percolator design enables the use of more finely ground
coffee particles, which maximizes the aroma extraction and enables a higher
flow rate to improve the extraction efficiency. This results in improved cof-
fee extract quality and significantly higher yield from the quantity of green
coffee beans used – which improves the process profitability and has the
potential to save manufacturers several millions of dollars per year in green
coffee bean procurement, depending on the size and capacity of the plant.
• The flow direction within the percolators is from bottom to top which sig-
nificantly reduces the risk of any blockages.
• The roast and ground coffee is moistened inside the percolator to ensure
aromas are not lost.
• For high quality extract, the system uses a dual-dual extraction mode,
which ensures primary aromas are gently extracted and preserved.
• Flash separation for off-flavor removal is carried out in a vacuum vessel for
higher process efficiency.
• The mixing of the aroma and coffee concentrate is carried out in-line which
provides more uniform results compared with tank mixing.
• SPX offers a choice of continuous belt vacuum freeze dryers and tray vac-
uum freeze dryers. Continuous belt freeze drying is ideal for smaller end-
product capacity and offers advantages over tray freeze drying in terms of
lower initial investment and lower operational costs. Improved efficiency is
also gained with no requirement to handle and transport trays or to clean,
wash and cool them after use. It has a capacity range of 100 kg/h – 250 kg/h.
• SPX continuous vacuum tray dryers offer a capacity range of 250 kg/h –
1,000 kg/h or higher.
• All SPX coffee plants are designed to meet specific customer requirements
with respect to capacity, plant configuration and plant layout. SPX instant
coffee plants further offer a fully automated solution with end-product
flexibility.
food Marketing & Technology • June 2013