GB2557369A

GB2557369A - Coffee processing system and method

Info

Publication number: GB2557369A
Application number: GB1703120.4A
Authority: GB
Inventors: Famuyibo Olakusibe; Krali Emiljana; Feng Ng Jian
Original assignee: Innov8 Coffee Ltd
Current assignee: Innov8 Coffee Ltd
Priority date: 2016-12-02
Filing date: 2017-02-27
Publication date: 2018-06-20
Also published as: GB201703120D0; GB201620550D0

Abstract

An apparatus for fermenting coffee beans in a fermentation process comprises: a fermentation vessel 110 having an outlet 120; means 126 for actuating contents of the fermentation vessel; a pH sensor 112 for monitoring the pH level in the fermentation vessel 110; and a control system 114. The control system 114 is arranged to control the means for actuating 126 in accordance with a regular actuation schedule, receive an output from the pH sensor and control at least the outlet of the fermentation vessel in response to at least the output from the pH sensor 112. Also disclosed are corresponding methods of controlling the fermentation of coffee beans and methods of collecting, analysing and using data arising from the fermentation process.

Description

(71) Applicant(s):

Ιηηονδ Coffee Ltd

Office 7, 35-37 Ludgate Hill, London, EC4M 7JN, United Kingdom (72) Inventor(s):

Olakusibe Famuyibo Emiljana Krali Jian Feng Ng (74) Agent and/or Address for Service:

Mathys & Squire LLP

The Shard, 32 London Bridge Street, LONDON, SE1 9SG, United Kingdom (51) INT CL:

A23F 5/02 (2006.01) A23F 5/16 (2006.01) (56) Documents Cited:

WO 2006/098733 A2

May 2015, Ιηηονδ Imperial wins McKinsey Venture Academy 2015, www.consultancy.uk [online]

Project coPHee, The James Dyson Foundation [online] (58) Field of Search:

INT CLA23F, A23G, G01N Other: WPI, EPODOC, Internet (54) Title of the Invention: Coffee processing system and method Abstract Title: Coffee processing system and method (57) An apparatus for fermenting coffee beans in a fermentation process comprises: a fermentation vessel 110 having an outlet 120; means 126 for actuating contents of the fermentation vessel; a pH sensor 112 for monitoring the pH level in the fermentation vessel 110; and a control system 114. The control system 114 is arranged to control the means for actuating 126 in accordance with a regular actuation schedule, receive an output from the pH sensor and control at least the outlet of the fermentation vessel in response to at least the output from the pH sensor 112. Also disclosed are corresponding methods of controlling the fermentation of coffee beans and methods of collecting, analysing and using data arising from the fermentation process.

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Coffee Processing System and Method

The present application is directed to methods and apparatus for the processing of coffee beans and, in particular, to the fermentation of coffee beans as part of a wet processing method and the control of the processing method.

When coffee cherries are picked from harvest, and ready for wet processing, they first go through the pulping stage and then go on to the processing stage (during which fermentation takes place). The ultimate goal of the fermentation stage is to get rid of the outer skin surrounding the coffee bean, and there are typically two main ways to do this; via fermentation, or via mechanical removal.

In the current landscape for wet processing coffee, there are 3 main techniques of processing which work towards this ultimate aim. These are Anaerobic wet processing, Aerobic wet processing, and Demucilaging.

Anaerobic wet processing: In this method, the pulped coffee beans are immersed under water for a period of up to 48 hours, during which time the enzymes secreted from the beans as a result of the fermentation chemical process naturally peel the outer skin layer of the coffee beans. Wet processing typically occurs following the rainy season at which point the beans have had enough time to absorb the necessary moisture before being processed. The wet processing method is typically valued for its added flavour characteristics over dry processing. The present application focuses on the Anaerobic fermentation process

Aerobic fermentation: In this method, the coffee beans are left to sit in the open over a lengthy period, during which time the process of fermentation also transpires albeit at a slower rate. Dry processing can occur year round out of rainy seasons and will typically require less effort.

Demucilaging: This form of fermentation employs machinery to rub the beans against each other and mechanically remove the outer skin layer.

Aspects of the invention are set out in the independent claims and preferred features are set out in the dependent claims. Preferred features of one aspect may be applied to other aspects and methods of operating the apparatus described and computer programs, computer program products or computer readable media for implemented the methods are also envisaged.

According to a first aspect, there is described herein apparatus for fermenting coffee beans in a fermentation process, the apparatus comprising:

a fermentation vessel having a further outlet and an outlet; means for actuating contents of the fermentation vessel; a pH sensor for monitoring the pH level in the fermentation vessel; and a control system arranged for:

controlling the means for actuating in accordance with a regular actuation schedule; receiving an output from the pH sensor; and controlling at least the outlet of the fermentation vessel in response to at least the output from the pH sensor.

Wet fermentation processing has hitherto been monitored and controlled by manual labour. The quality of the fermented beans has therefore depended significantly on the farmer’s intuition, experience and attentiveness, has required significant input in terms of his time and has left room for inconsistencies and human error. This can reduce the proportion of high quality beans in a particular fermentation batch and make it difficult to ensure consistent quality between batches. Furthermore, farmers and producers in different areas use different techniques to control the processing of the coffee, leading to inconsistencies between areas.

The claimed system provides an apparatus for automating some of the control of a fermentation process. Furthermore, the system created a controlled fermentation environment to help coffee beans reach an optimum quality. In particular, monitoring the pH level during the fermentation process and controlling when the fermentation process ends by controlling the outlet of the fermentation vessel enables a more consistent product and provides quality assurance for the buyer. Furthermore, the use of an actuation means can enable regular scheduled stirring of the contents of the fermentation vessel, enabling a more consistent fermentation process for all of the coffee beans.

In particular embodiments, as described in more detail below, the apparatus and associated methods introduce parameters, sensors, automation and data to accurately monitor the quality and fermentation process. Sensors are controlled by algorithms with pre-set parameters to detect and automate the fermentation. Unlike conventional means of coffee processing, embodiments detect the changes in the coffee fermentation. Once it reaches an optimal level of quality, embodiments automatically release the solution to stop further fermentation. This reduces unnecessary wastage caused by the fermentation and creates better quality coffee beans. As also described in more detail below, communication modules, such as GSM modules allow data to be captured, providing transparency to the entire coffee processing cycle. Exporters and buyers of the coffee can then pre-determine the quality of the coffee beans through an online platform.

In a preferred embodiment, the pH sensor is arranged for continuous or frequent monitoring of the pH level, preferably wherein frequent monitoring comprises obtaining a reading of the pH level at least once in each half hour, preferably at least once every 10 minutes, further preferably at least once every 5 minutes.

Continuous, or at least frequent, pH readings enable accurate control of the fermentation process through its impact on the pH level of the contents of the fermentation vessel. The fermentation process can be stopped as soon as the pH level has stabilised at a predetermined value. Like the values of other parameters described herein, the value of the pH level can be set manually for an individual fermentation process or can be set according to parameter values pre-stored in a memory associated with the apparatus or according to a configuration file received from a remote system.

In a preferred embodiment, the further outlet comprises a valve for draining fluid from the fermentation vessel. The further outlet may include a mesh covering or filter to prevent solid contents of the fermentation vessel from exiting the vessel when the further outlet is open. Typically, the fluid in which the fermentation process is taking place is changed several times during the fermentation of a single batch of coffee beans.

In one embodiment, the outlet comprises a valve for draining fluid and solid matter from the fermentation vessel. The outlet is typically opened at the end of the fermentation process to retrieve the fermented coffee beans from the vessel and empty the vessel of beans and fluid ready for fermentation of a new batch of beans.

The outlets described herein may comprise electromechanical valves operable on receipt of a command from software running on the microprocessor.

In one embodiment, the apparatus further comprises a temperature sensor for supplying a temperature sensor output to the control system. Temperature is an important factor in the process of fermenting coffee beans and providing a temperature sensor can enable the producer to track the fermentation process and optimise it to improve the quality of the coffee produced. In particular, as described in more detail below, the temperature can rise as the fermentation process starts to take place within the vessel.

The temperature within the fermentation vessel affects the duration of the fermentation. At higher temperatures, the coffee ferments quicker. Lower temperatures can lead to a longer fermentation. For instance, a lower temperature of 15 degrees, as compared to 30 degrees, could add one or more days to the fermentation. Heating means can be provided to keep the temperature of the fermentation vessel within an optimal range, for example at a temperature of greater than 20 degrees, preferably greater than 25 degrees, preferably around 30 degrees. However, in climates where the ambient temperature is relatively high it will be appreciated that a heater is unlikely to be necessary at least during the day. The heating means can comprise any suitable heating means such as direct electrical or gaspowered heating or a more indirect heating means such as water or oil-based heating. Optionally, the means for heating may be incorporated within or attached to the actuation device or stirrer.

Preferably, the apparatus further comprises an oxygen sensor for supplying an oxygen sensor output to the control system. The oxygen sensor determines the level of dissolved oxygen within the contents of the fermentation vessel.

In one embodiment, the apparatus further comprises means for supplying an oxygenenriched gas to the fermentation vessel. This may be a supply of pure oxygen, an oxygenenriched gas or simply air from external sources, which will have a higher concentration of oxygen than air within the fermentation vessel once fermentation has started. Oxygen supply controls can be fed back into the control system so that the control system can supply further oxygen to the system in response to changes in the oxygen level in the vessel. In some embodiments, a further oxygen sensor may be provided to monitor oxygen levels in the gas above the fermenting contents of the vessel.

Optionally, the control system controls at least the further outlet of the fermentation vessel in response to the output from the oxygen sensor. This can enable the fermentation process to be controlled and adjusted during the process, in particular by selectively draining fluid when the oxygen dissolved within the vessel falls below a certain threshold, which is a predetermined threshold value. Optionally, the system monitors the dissolved oxygen level and controls the further outlet only once the oxygen level has fallen below a predetermined threshold value for a certain period of time, for example 2 minutes. Controlling the further outlet includes opening the further outlet to enable the excise of material from the fermentation vessel.

Optionally, the sensitivity of the pH sensor is at least 0.5, preferably at least 0.02, further preferably at least 0.01.

Optionally, the outlet is controlled in response to the value of the output from the pH sensor falling below a predetermined pH threshold. Ultimately, the opening of the outlet, thereby terminating the fermentation of the coffee beans, is controlled according to the pH level in the fermentation vessel. When the pH level falls below a set pH threshold value, the outlet is opened and the coffee exits the fermentation vessel together with the fermentation liquid.

In one embodiment, the means for actuating comprises a mechanical stirrer. Preferably, the stirrer is shaped to move the coffee beans around within the fermentation vessel when it is operated. Preferably, the stirrer is actuated in such a way that beans throughout the vessel are moved and the stirrer reaches all parts of the vessel.

Optionally, the stirrer can provide heat to the contents of the fermentation vessel to enable the contents to be maintained within an optimum temperature range. For example, an electrical element may be provided in the stirrer, or the stirrer may be heated using a water or oil-based heating system.

Optionally, the regular actuation schedule causes the means for actuating to operate at least once every hour, preferably at least once every half hour, further preferably at least once every 10 minutes. Frequent actuation or stirring of the contents of the fermentation vessel enables all of the coffee beans in a batch to be fermented equally.

Optionally, the apparatus further comprises a timer and the further outlet and/or the outlet is controlled further in response to an output from the timer. For example, in some embodiments the first and/or outlets are opened only once the pH or temperature has stabilised at the threshold level, for example has been above or below the threshold level for a predetermined period of time. This may be determined by means of a timer or simply by requiring a number of consecutive reading from the sensor at a particular level.

In one embodiment, the apparatus comprises a timer and a temperature sensor and the outlet is controlled in response to outputs from the timer, the temperature sensor and the pH sensor. In particular, the control system may be arranged to open the outlet in response to the value of the output from the pH sensor, the temperature sensor and/or the timer exceeding a respective threshold value. In this embodiment, therefore, the outlet is opened either when the pH has fallen below a threshold level and the temperature has risen above a particular level or when the pH has fallen below a threshold level.

Preferably, the apparatus further comprises a memory for storing a fermentation data set for the fermentation process, the fermentation data set including the output from the pH sensor. Preferably, the fermentation data set further includes at least one of temperature readings obtained during the fermentation process, a measure of the level of dissolved oxygen in the fermentation vessel, a record of parameter values at the time the first and outlets are operated, an identifier of the type and/or quantity of coffee bean being fermented, an identifier of the composition and/or volume of a fermentation liquid added to the fermentation vessel, an identifier of the location of the apparatus, an identifier of the apparatus, an identifier of the owner or operator of the apparatus and an environmental factor outside the fermentation vessel such as humidity, temperature and altitude of the fermentation vessel.

Preferably, the apparatus further comprises a communications interface for communicating the fermentation data set to a remote system.

Preferably, the apparatus further comprises a communications interface for receiving at least one parameter or threshold from a remote system.

Preferably, the communications interface for communicating is the same as the communications interface for receiving. The remote system may be a central control and monitoring system as described herein. The communications interface may comprise a wireless or wired interface, for example a GSM (Global System for Mobile Communications Standard), GPRS (General Packet Radio Service), WAN (Wide Area Network), LAN (Local Area Network) interface or a wired or fibre-connected interface. The communications interface provides a connection to a system with a user interface, for example an application (app) operating on a mobile communications device such as a user’s mobile telephone or tablet. The user interface preferably enables the monitoring and control of parameters and timings via the user device, including turning the system on or off, operating the valves and heating or oxygenating the system. The user interface can also be used to set starting and operating control parameters for the system, for example the frequency and period of operation of the actuation means, the pH and dissolved oxygen values at which the valves are operated and the frequency at which data is collected. The user interface can also be used to obtain from the user or directly from the system itself information about the coffee and the fermentation process, for example information about the type and/or quantity of coffee beans in the vessel, the altitude at which the system is operating, timing information for the process and information about external environmental factors.

A method of operating the apparatus described above, optionally together with each of the preferred features, is also provided in the present application.

According to a further aspect, there is provided a method for controlling the fermentation of coffee beans in a fermentation vessel comprising a plurality of sensors, the fermentation vessel containing coffee beans and a fermentation liquid comprising water, the method comprising:

measuring with the plurality of sensors a plurality of parameters relating to the fermentation process, the parameters including the pH of the contents of the fermentation vessel;

monitoring at a control system the value of a first parameter and performing a first action when the value of the first parameter passes a first predetermined threshold; and monitoring at the control system the value of the pH and performing a second action to terminate the fermentation process when the value of the pH reaches a second predetermined threshold.

Preferably, the plurality of parameters includes parameters selected from the group comprising: temperature and dissolved oxygen level.

Optionally, the first parameter comprises a measure of the oxygen dissolved in the fermentation vessel. In particular, the first action may be taken when the level of dissolved oxygen falls below a predetermined threshold.

Optionally, the first action comprises replacing the fermentation liquid in the fermentation vessel and, optionally, the second action comprises terminating the fermentation process.

In one embodiment, the second action comprises determining whether a measure of temperature in the fermentation vessel has reached a threshold value and terminating the fermentation process if the measure of temperature has reached the threshold value.

Optionally, the second action comprises determining whether a measure of temperature in the fermentation vessel has reached a threshold value and, if the measure of temperature has not reached the threshold value, waiting for a predetermined period of time before terminating the fermentation process. This enables the fermentation process to end even if the temperature does not quite meet the threshold value, since the pH value is more important to the quality of the end product than the processing temperature.

The method may further include periodically capturing the values of the plurality of parameters. The captured values may be stored as a fermentation data set for the fermentation system.

Optionally, the method also includes exporting the captured values of the parameters to a central server and storing the captured values together with an identifier associated with the fermentation vessel.

In one embodiment, the values of the first and the second thresholds are set through a control system prior to the start of the fermentation process. The control system is preferably local to the fermentation vessel.

Optionally, the first and second thresholds are set manually by a user through the control system.

Alternatively, the first and second thresholds are set automatically by the control system based on feedback obtained from previous fermentation processes in the fermentation vessel or in other fermentation vessels.

The method preferably further includes the step of periodically actuating the contents of the fermentation vessel during the fermentation process according to a predefined schedule. Periodically actuating preferably includes automatically actuating the contents using an automatic actuator controlled by the control system.

According to a further aspect, there is provided a method for controlling a coffee fermentation process in a plurality of distributed fermentation systems, the method comprising:

receiving from each fermentation system at least one fermentation data set, the fermentation data set including values of a plurality of parameters measured during a fermentation process performed by the fermentation system;

receiving a quality measure associated with the coffee produced by each fermentation system;

correlating each fermentation data set with the quality measure associated with the coffee produced by the fermentation system that generated the fermentation data set; and generating a plurality of control parameters for a fermentation system based on the correlations between the quality measures and the fermentation data sets.

The method preferably takes place at a central control system that receives data from a plurality of fermentation systems.

Optionally, the method further comprises transmitting the control parameters to the fermentation system to enable the adjustment of control parameters at the fermentation system.

Optionally, the method also includes outputting a fermentation data set associated with a particular fermentation process.

In one embodiment, the fermentation data set includes a measure of the pH in a fermentation system over time. In particular, the final pH value obtained by the fermentation system prior to stopping the fermentation process.

Optionally, the fermentation data set further includes at least one of temperature readings obtained during the fermentation process, a measure of the level of dissolved oxygen in the fermentation vessel, a record of parameter values at the time the first and outlets are operated, an identifier of the type and/or quantity of coffee bean being fermented, an identifier of the composition and/or volume of a fermentation liquid added to the fermentation vessel and an environmental factor outside the fermentation vessel such as humidity, temperature and altitude of the fermentation vessel.

A central control system and is also envisaged for implementing the method aspect set out above, optionally with any of its preferred features, and individual fermentation systems that are networked or communicatively coupled to the central control system are also provided.

According to a further aspect, there is provided a method of controlling a coffee fermentation process in one of a plurality of fermentation systems, the method comprising:

storing in a database a plurality of fermentation data sets obtained from a plurality of fermentation processes;

storing an indication of the coffee grade for the coffee produced by each fermentation process, the coffee grade being associated with a fermentation data set;

receiving a request for a plurality of process parameters, the request including data relating to a particular fermentation system;

analysing the stored fermentation data sets to determine the plurality of process parameters for the particular fermentation system; and outputting the plurality of process parameters for use by the requesting fermentation system in the particular fermentation process.

Optionally, analysing the stored fermentation data sets includes obtaining a measure of the fit of the data relating to the particular fermentation system to data relating to one or more stored fermentation data sets and optimising the indication of the coffee grade among the fitted fermentation data sets.

According to a further aspect, there is also provided a method for determining a predicted grading for a batch of processed coffee, the method comprising:

storing in a database a plurality of fermentation data sets obtained from a plurality of previous fermentation processes;

receiving a fermentation data set associated with the batch of processed coffee; analysing the stored fermentation data sets to compare the received the fermentation data set to the plurality of stored fermentation data sets;

wherein analysing the plurality of previous fermentation data sets comprises determining one or more closest-matching fermentation data sets;

outputting one or more predicted grades associated with the one or more closestmatching fermentation data sets.

Optionally, outputting one or more grades comprises outputting a single predicted grade for the coffee. Optionally, outputting one or more predicted grades comprises outputting a grade data set for the coffee.

Optionally, the grade data set includes at least one of: an overall coffee grade, a predicted grade relating to the coffee taste, aroma, acidity, finish, bitterness, body or flavour.

In one embodiment, analysing the stored fermentation data sets includes obtaining a measure of the fit of the received fermentation data set to the plurality of previous fermentation data sets.

Optionally, determining one or more closest-matching data sets comprises determining a plurality of fitted data sets and wherein outputting one or more grades comprises outputting a range of grades for the coffee.

In one embodiment, outputting one or more grades comprises outputting a measure of the error associated with the grade determined in the analysis.

Preferably, any of the fermentation data sets described herein may include data relating to the particular fermentation system or fermentation process that produced the fermentation data set. For example the fermentation set may include information relating to the location of the fermentation system, an identifier of the particular fermentation system and/or an identifier of the owner of the particular fermentation system. Further preferably, the data relating to the particular fermentation system includes data relating to the coffee bean being fermented in the fermentation system, optionally including coffee bean type, coffee bean origin and parameters relating to the pre-processing of the coffee bean.

Optionally, the data relating to the particular fermentation system includes data relating to the conditions of the system, for example the altitude of the fermentation system, the temperature and/or humidity in the environment surrounding the system.

Optionally, the plurality of process parameters includes a pH threshold value, a temperature threshold value and/or a dissolved oxygen level threshold value.

Optionally, the fermentation data set includes sensor readings obtained from a plurality of sensors operating during the fermentation process.

The system and methods described herein are implemented with dynamic feedback and adjustment of the fermentation process. As previously noted, the valves operate in response to measured conditions within the fermentation vessel. Furthermore, external factors such as temperature or the oxygen level within the vessel may be monitored and controlled using heating means and oxygen supply means. However, in addition, parameters that control the operation of the system may also be adjusted dynamically in response to other factors. For example, if a fermentation process is happening more quickly than expected, the threshold at which the dissolved oxygen level triggers the opening of a valve may be increased to cause a more frequent refreshing of the fluid within the vessel, potentially slowing down the fermentation process. Alternatively, the target pH level that controls the time at which the fermentation process is brought to an end may be reduced to enable the fermentation process to run for a little longer.

Embodiments of the systems and methods are described herein with reference to the drawings in which:

Figure lisa schematic diagram of a fermentation system according to one embodiment; Figure 2 illustrates a coffee bean processing method according to one embodiment;

Figure 3a is a schematic illustration of the change in temperature during the fermentation process according to one embodiment;

Figure 3b is a schematic illustration of the change in pH level in a fermentation vessel during the fermentation process according to one embodiment;

Figures 4a-4g provide schematic diagrams of a second embodiment of a fermentation system;

Figure 5 illustrates an interconnected network of fermentation systems having a central monitoring and control system according to one embodiment;

There is described below a fermentation system according to one embodiment, followed by a description of a typical fermentation process.

Figure 1 illustrates a coffee fermentation system according to one embodiment. The system includes a fermentation tank or vessel 110 into which is placed a batch of coffee beans that are ready for fermentation and a fermentation liquid, typically water. A pH sensor is 112 suspended inside the fermentation tank and is programmed to frequently or preferably constantly read the water to track changes in the pH level. The pH sensor is connected via a data connection to a microprocessor 114 where the sensor logic resides. Preferably, the temperature is sensed at least every 15 minutes, preferably at least every 5 minutes and further preferably continuous monitoring is provided.

The microprocessor component 114 serves the function of managing interactions and providing instructions between the sensors, valve system, stirrer, etc. The microprocessor also includes a data logging module and data export GSM shield 124 or other communications interface as described herein. The microprocessor 114 may also be provided with an output to an LCD screen or the ability to connect a laptop or other computing device to enable extraction or input of data and programming of the microcomputer.

A typical pH sensor 112 that could be used in the illustrated fermentation system is a H-101 pH electrode with a range of 0-14 pH and a sensitivity of 0.02pH operating within a temperature range of 0-60 degC.

An automated stirrer 126 or actuator is provided and this is powered by a single speed motor. A typical cycle programmed into the code for the stirrer would be a looping runtime whereby the stirrer will run for 5 min every 30 min. Both the runtime of the stirrer (currently 5 min) and the idle time (currently 30 min) are changeable within the code.

In the present embodiment, a temperature sensor 116 is also suspended inside the fermentation tank and held in a static position. This sensor is programmed to frequently or constantly read the water and track the changes in the temperature. This sensor also feeds information back to the microprocessor 114 where the sensor logic resides. Preferably, the temperature is sensed at least every 15 minutes, preferably at least every 5 minutes and further preferably continuous monitoring is provided. The temperature sensor is not essential in every embodiment of the system, however.

In the present embodiment, a dissolved oxygen sensor 118 is also suspended inside the fermentation tank and held in a static position. It is programmed to constantly read the oxygen level in the water and track the changing levels of oxygen over the operating cycle. This sensor feeds information back to the microprocessor where our sensor logic resides. The dissolved oxygen sensor is not essential in every embodiment of the system, however.

A first valve 120 to a further outlet is provided and controlled via the code stored in the microprocessor 114. In this embodiment the outlet includes a ball valve, is fitted with a mesh inner lining and is operated through instructions from the microprocessor, while receiving power from the 12V battery source 128. When the ball valve is opened, the mesh lining only allows water to flow through and stops the mucilage and coffee beans from falling out. This valve is intended to allow the water to be refreshed during the fermentation cycle. Refreshing the water two or three times during fermentation is important to enable the chemical reactions to continue and not be halted by oxygen levels. The adjustable feature of this component is the length of time the valve will stay opened for and we calibrate this based on the size of the tank which will be matched with the flow rate of the valve to find an optimum point.

A second valve 122 to an outlet is provided and controlled via the code stored in the microprocessor. In this embodiment, the outlet includes a ball valve that does not have a mesh lining and is operated through instructions from the microprocessor, while receiving power from the 12V battery source. When the ball valve is opened, all the content of the tank flows out (including water, mucilage, coffee beans). This valve is intended to drain the tank to stop the fermentation process. The adjustable feature of this component is the length of time the valve will stay opened for and we calibrate this based on the size of the tank which will be matched with the flow rate of the valve to find an optimum point.

There are one or two 12V Lithium-Ion batteries 128 working in sync to power all the components within the device. These batteries are rechargeable via wall sockets or any power supply such as renewable energy sources. The energy output of these batteries is converted according to the voltage requirement of the components as in some cases the voltage needs to be stepped down; from a 12V to a 9V equivalent energy source for instance (as illustrated in the diagram). The skilled person will appreciate that, while batteries are shown in the present system, and may be particularly advantageous in rural coffee processing plants where power supply can be unreliable and erratic, other power sources, such as a mains-based power source or a renewable energy source, could also be used to power the present system.

The microprocessor is fitted with a memory card module, in this case an SD card, which stores the running memory of the device. When settings are set for the various components (sensors, stirrer, motor valve) these are saved onto the memory card and the device operates from the last saved settings once turned on. The memory card module, or other suitable connected data storage device, can also be used to store readings obtained from the sensors of the system during operation. These readings can then be obtained by the system operator or uploaded to a remote location for storage and further analysis, as described herein in more detail. It will be appreciated that, in some implementations where a data connection is reliable, it would be possible to omit the memory card module and rely instead on the immediate upload of data to a remote system or to a more local storage device.

In one particular implementation, a storage device is connected to the microprocessor via a short range communications interface, such as a Bluetooth™ or other wireless connection. Data gathered by the microprocessor may be continuously or periodically transmitted over the short range communications interface to a separate device, such as a mobile telephone or tablet device.

The present system is also provided with a GSM shield 124 that transmits sensor readings via radio waves to a receiver system. The output format of the present system is alpha numeric characters of any length (similar to text facility on a mobile device). However, the type and format of the output data is governed largely by the capabilities of the microprocessor, the amount and type of storage available and the capabilities of the interface for transmitting the data. The use of alphanumeric characters, however, enables the cost-effective transmission of a large amount of data over a relatively narrow bandwidth.

The separate or receiver device (not shown) to which readings are transmitted will typically include a user interface, preferably an application (app) on a mobile device, computer or tablet. In one implementation, the separate device receives and stores information from the fermentation system for subsequent upload into a central control system. Alternatively or in addition, the app enables control of the fermentation system itself, in particular by enabling the setting of parameters of operation of the fermentation system (pH levels and dissolved oxygen levels at which the valves operate, timing values etc.). These parameters are typically set using the app and transmitted to the fermentation system prior to the start of a new fermentation process, although it will be appreciated that the parameters may be adjusted during the running of a fermentation process if necessary.

The skilled person will appreciate that variations to the processing system described above may be provided within the scope of the claims. For example other actuation means may be used in place of the stirrer.

In one alternative embodiment, one or more of the sensors described above is attached to or implemented within the stirrer or actuator. Providing sensors with the stirrer can ensure that, once the stirrer is operating, the readings given by the sensor are more homogenous and more reflective of the measurements throughout the content of the fermentation vessel. Alternatively, several sensors can be provided at different points within the fermentation vessel.

A fermentation method according to one embodiment will now be described with reference to Figure 2.

After the cherries are pulped, they are guided down the canal with rakes into the fermentation tank 210. Any water from the canal which has follow the beans is filtered out of the beans to avoid contamination of the tank. Fresh water is then poured into the fermentation tank until all the beans are submerged 212. Any water added to the tank is first passed through a water filter to ensure that water entering the system, which may come from a river or water pump, is relatively clean and free of particulates. The beans are left to ferment in the water and the dissolved oxygen meter constantly tracks the level of oxygen in the tank 214. The pH and temperature sensor also track the respective levels in the tank. The stirrer runs 216 for 5min every 20min on a loop, until the fermentation process ends.

Once the oxygen reading reaches the level we have set (which is an adjustable parameter within the system) 218, an action is sent to the valve with the mesh lining (at the further outlet) to open up and release only the fermentation liquid 226. This is likely to be around 12 hours from the beginning of the fermentation process, but the action is governed by the dissolved oxygen sensor and not by any timer.

New water is then added to the fermentation tank 212 to submerge the beans and the fermentation of the beans continues. The dissolved oxygen meter continues to track the changing level of oxygen in the tank and the pH sensor and temperature sensor also continue to collect data 214. The stirrer continues to stir the contents of the fermentation tank according to its regular cycle 216.

At this point, the pH level will have begun to climb down steadily. The temperature level falls whenever water is replenished, and rise as the chemical process of fermentation takes place (so we expect it to rise and fall in a cyclical manner over the process). The change in the pH level and temperature level is illustrated schematically in Figures 3a and 3b.

Once the oxygen reading reaches the level we have set once again (which can be adjusted and which is likely to be, but may not be the same value as the level for the first water change), an action is sent to the valve with mesh lining at the further outlet to open up and release only the fermentation liquid 226. Again, the water is replaced and the cycle restarts 212.

This cycle is repeated until the pH level and temperature are both within the range that has been set by the control system 220, 212, that is both measures have reached their threshold values.

Once the pH level and temperature have reached within the ranges set, an action is sent to the valve without mesh at the outlet to open and release all the contents of the tank 224. The contents are flushed them out into a canal to stop the fermentation process and continue with the washing process.

Optionally, if the pH value has reached the desired threshold level but the temperature has not reached its threshold value, the system may wait a number of minutes, for example 5 minutes, while constantly measuring the temperature 228. If the threshold temperature value is reached during that time, the fermentation process ends by opening the second valve 224. If the threshold temperature value is not reached by the end of the time, the fermentation process is stopped anyway by opening the outlet to remove the contents from the fermentation tank.

Typically, the whole fermentation process is likely to take four cycles of around 12 hours, so around 48 hours in total. However, control of the process is governed by the sensor values and not by any timing. The time taken for the fermentation process to complete will depend in part on the altitude of the system; the higher the altitude, the longer the time taken for the fermentation process to take place. At altitudes of above 2000 metres, the process can take up to 72 hours.

Figures 4a to 4g are schematic illustrations of a further embodiment of the present system.

It is further noted that the skilled person will appreciate that the system described herein may be retrofitted to an existing fermentation tank or vessel. In particular, the sensor array, microprocessor and control valve may be fitted to a fermentation tank in situ. A retrofit device may be provided with an integral stirring system, or the stirring system may be implemented in a separate system.

Figure 5 illustrates a plurality of fermentation systems 512, 514, 516 each of which includes a communication link to enable it to communicate with a central control and monitoring system 510. The central control and monitoring system includes means for storing data 520 relating to each connected fermentation system and other information such as control parameter settings. In the illustrates embodiment, the means for storing is an external database connected to the central system, but the skilled person will appreciate that any suitable local, network connected or cloud based storage system may be provided.

The central control and monitoring system also includes an interface 522 for direct input of data into the system and for display of information to the user. As described in more detail below, the interface enables the input of quality data relating to batches of processed coffee.

In one embodiment, the communication links between the fermentation systems and the central system may be a one-way link or “download” link that enables each fermentation system to transmit data comprising a fermentation data set, to the central control and monitoring system. However, in the present embodiment, the links are two-way links to enable the download of data from the fermentation system and the upload of parameter settings, control information and software updates to the fermentation systems.

The types of communication link may vary between fermentation systems, but include wired connections, internet-based connections 518 and wireless connections or a combination of such links as appropriate for the particular set up of the fermentation system. In rural areas, it may be particularly useful to provide a wireless interface such as a GSM/GPRS/GPS/3G modem coupled to the fermentation system to enable communication across a telecommunications network. Alternatively, an IP-based wireless communication device such as a wireless router, may be used to transmit and receive data onto an IP-based network such as the Internet.

In one embodiment, the fermentation vessel or system has an interface (such as a short range NFC interface) to enable connection to a mobile wireless device (such as a mobile telephone) and the mobile wireless device then communicates with the central control and monitoring system over a telecommunications or IP network.

As noted above, fermentation data sets are gathered by the central control and monitoring system from each fermentation system or vessel. The fermentation data sets comprise information relating to the conditions during the fermentation process for a particular batch of coffee beans. For example, the fermentation data sets include at least some of the following including details of how they change over time throughout the fermentation process:

a measure of the pH in a fermentation system over time - temperature readings obtained during the fermentation process a measure of the level of dissolved oxygen in the fermentation vessel a record of parameter values at the time the first and outlets are operated an identifier of the type and/or quantity of coffee bean being fermented an identifier of the composition and/or volume of a fermentation liquid added to the fermentation vessel environmental factors outside the fermentation vessel such as humidity, temperature and altitude of the fermentation vessel

Once a batch of coffee beans has been processed through the fermentation system, a sample is retrieved and tested by coffee taste-testers in a “cupping” process so that it can be graded according to factors including its taste, aroma, acidity, finish, bitterness, body (e.g. light roast or dark roast) and flavour including nuttiness and sharpness. The grade of the batch of coffee is determined and associated with the fermentation data set for that particular batch of coffee, in particular by inputting the grade into the database of the central control and monitoring system. Not every fermentation data set that is stored in the central system may have an associated grade.

As the skilled person will appreciate, the database of the central control and monitoring system builds up over time a number of fermentation data sets and associated grades for the resulting coffee. It is therefore possible to analyse the stored data to determine a number of different results. In particular, optimal parameters for coffee fermentation may be determined for a particular type of coffee bean, a particular producer and/or particular climatic or environmental conditions in order to increase the likelihood of the processed coffee achieving the highest grade possible for that coffee. For a particular type of coffee or a particular producer, the system can determine parameters and control settings and can output these as a data file directly to a requesting fermentation system so that optimal parameters are used in processing the next batch of coffee.

A particular coffee producer may obtain and review his fermentation data sets and these can be analysed to inform him of which settings and parameters resulted in the best coffee grading, and which of those parameters had the largest impact on the grading, to enable him to fine-tune manually the coffee fermentation process.

The fermentation data sets and associated grades can also be used by coffee purchasers. In particular, rather than taste-testing each batch of coffee, the fermentation data set of a particular batch of coffee can be compared to the fermentation data set of already-graded batches of coffee. The data sets are analysed to determine one or several stored data sets that match the fermentation data set of a particular batch to within a predefined error range. Then the grades associated with the one or more matching data sets can be retrieved. The producer can be assured that the quality of the new batch is likely to be similar to the previously graded batch(es) and the purchase price can be set accordingly.

The analysis of matches between data sets can be done by an algorithm that determines the “fit” between factors such as:

the temperature profile as it changes throughout the fermentation process

- the profile of the dissolved oxygen level during the fermentation process

- the profile of the pH level during the fermentation process starting and finishing values of the pH, temperature and/or dissolved oxygen level

- the timing of the opening of the first and outlets and the number of times the fermentation liquid is replaced during the fermentation process an identifier of the type of coffee bean an identifier of the coffee producer an identifier of the type of fermentation vessel used

- values of factors in the external environment before and during the fermentation process for example including temperature, humidity and altitude a measure of the consistency of the grading of coffee obtained from a particular producer

Interactions between these factors may also be taken into account and some may carry a heavier weighting in the analysis. For example, a fermentation process taking place at a higher altitude is likely to take longer than one taking place at a lower altitude and this may be factored in to the timing information obtained for each of the profiles. Particularly important factors to “fit” between data sets include the ending pH level and the identifier of the type of coffee bean.

The fermentation systems and apparatus described herein has the capacity to be scaled down for smallerholder farmer communities or scaled up for large scale wet processing mills, such as those under cooperatives, to help deliver speciality grade coffee from their production processes. By empowering farmers to monitor quality during processing, the system can improve exportable output an increase the yield from their harvest.

Claims

1. An apparatus for fermenting coffee beans in a fermentation process, the apparatus comprising:

a fermentation vessel having an outlet;

means for actuating contents of the fermentation vessel;

a pH sensor for monitoring the pH level in the fermentation vessel; and a control system arranged for:

2. The apparatus according to claim 1 wherein the pH sensor is arranged for continuous or frequent monitoring of the pH level, preferably wherein frequent monitoring comprises obtaining a reading of the pH level at least once in each half hour, preferably at least once every 10 minutes, further preferably at least once every 5 minutes.

3. The apparatus according to any preceding claim wherein the outlet comprises a valve for draining fluid and solid matter from the fermentation vessel.

4. The apparatus according to any preceding claim further comprising a temperature sensor for supplying a temperature sensor output to the control system.

5. The apparatus according to any preceding claim further comprising an oxygen sensor for supplying an oxygen sensor output to the control system.

6. The apparatus according to any preceding claim further comprising a further outlet, wherein the further outlet comprises a valve for draining fluid from the fermentation vessel.

7. The apparatus according to claim 6 wherein the control system controls at least the further outlet of the fermentation vessel in response to the output from the oxygen sensor.

8. The apparatus according to any preceding claim wherein the sensitivity of the pH sensor is at least 0.5, preferably at least 0.02, further preferably at least 0.01.

9. The apparatus according to any preceding claim wherein the outlet is controlled in response to the value of the output from the pH sensor falling below a predetermined pH threshold.

10. The apparatus according to any preceding claim wherein the means for actuating comprises a mechanical stirrer.

11. The apparatus according to any preceding claim wherein the regular actuation schedule causes the means for actuating to operate at least once every hour, preferably at least once every half hour, further preferably at least once every 10 minutes.

12. The apparatus according to any preceding claim further comprising a timer and wherein the further outlet and/or the outlet is controlled further in response to an output from the timer.

13. The apparatus according to any preceding claim wherein the apparatus comprises a timer and a temperature sensor and wherein the outlet is controlled in response to outputs from the timer, the temperature sensor and the pH sensor.

14. The apparatus according to any preceding claim wherein the control system is arranged to open the outlet in response to the value of the output from the pH sensor, the temperature sensor and/or the timer exceeding a respective threshold value.

15. The apparatus according to any preceding claim further comprising a memory for storing a fermentation data set for the fermentation process, the fermentation data set including the output from the pH sensor.

16. The apparatus according to claim 15 wherein the fermentation data set further includes at least one of:

temperature readings obtained during the fermentation process; a measure of the level of dissolved oxygen in the fermentation vessel; a record of parameter values at the time the first and outlets are operated; an identifier of the type and/or quantity of coffee bean being fermented; an identifier of the composition and/or volume of a fermentation liquid added to the fermentation vessel;

an identifier of the location of the apparatus; an identifier of the apparatus;

an identifier of the owner or operator of the apparatus; and an environmental factor outside the fermentation vessel such as humidity, temperature and altitude of the fermentation vessel.

17. The apparatus according to claim 15 or 16 further comprising a communications interface for communicating the fermentation data set to a remote data storage device.

18. The apparatus according to any preceding claim further comprising a communications interface for communicating the fermentation data set to a remote system.

19. The apparatus according to any preceding claim further comprising a communications interface for receiving at least one parameter or threshold from a remote system.

20. A method for controlling the fermentation of coffee beans in a fermentation vessel comprising a plurality of sensors, the fermentation vessel containing coffee beans and a fermentation liquid comprising water, the method comprising:

monitoring at a control system the value of a first parameter and performing a first action when the value of the first parameter passes a first predetermined threshold;

monitoring at the control system the value of the pH and performing a second action to terminate the fermentation process when the value of the pH reaches a second predetermined threshold.

21. The method of claim 20 wherein the plurality of parameters include parameters selected from the group comprising: temperature and dissolved oxygen level.

22. The method of claim 20 or 21 wherein the first parameter comprises a measure of the oxygen dissolved in the contents of the fermentation vessel.

23. The method of any of claims 20 to 22 wherein the first action comprises replacing the fermentation liquid in the fermentation vessel.

24. The method of any of claims 20 to 23 wherein the second action comprises terminating the fermentation process.

25. The method of any of claims 20 to 24 wherein the second action comprises determining whether a measure of temperature in the fermentation vessel has reached a threshold value and terminating the fermentation process if the measure of temperature has reached the threshold value.

26. The method of any of claims 20 to 25 wherein the second action comprises determining whether a measure of temperature in the fermentation vessel has reached a threshold value and, if the measure of temperature has not reached the threshold value, waiting for a predetermined period of time before terminating the fermentation process.

27. The method of any of claims 20 to 26 further comprising periodically capturing the values of the plurality of parameters.

28. The method of any of claims 20 to 27 further comprising exporting the captured values of the parameters to a central server and storing the captured values together with an identifier associated with the fermentation vessel.

29. The method of any of claims 20 to 28 wherein the values of the first and the second thresholds are set by a control system prior to the start of the fermentation process.

30. The method of any of claims 20 to 29 wherein the first and second thresholds are set manually by a user through the control system.

31. The method of any of claims 20 to 30 wherein the first and second thresholds are set automatically by the control system based on feedback obtained from previous fermentation processes in the fermentation vessel or in other fermentation vessels.

32. The method of any of claims 20 to 31 further comprising receiving a configuration file from a remote system to set the first and second thresholds.

33. The method of any of claims 20 to 32 further comprising periodically actuating the contents of the fermentation vessel during the fermentation process according to a predefined schedule.

34. The method of claim 33 wherein periodically actuating comprises automatically actuating the contents using an automatic actuator controlled by the control system.

35. A method for controlling a coffee fermentation process in a plurality of distributed fermentation systems, the method comprising:

36. The method according to claim 35 further comprising transmitting the control parameters to the fermentation system to enable the adjustment of control parameters at the fermentation system.

37. The method according to claim 35 or 36 further comprising outputting a fermentation data set associated with a particular fermentation process.

38. The method according to any of claims 35 to 37 wherein the fermentation data set includes a measure of the pH in a fermentation system over time.

39. The method according to any of claims 35 to 38 wherein the fermentation data set further includes at least one of temperature readings obtained during the fermentation process, a measure of the level of dissolved oxygen in the fermentation vessel, a record of parameter values at the time the first and outlets are operated, an identifier of the type and/or quantity of coffee bean being fermented, an identifier of the composition and/or volume of a fermentation liquid added to the fermentation vessel and an environmental factor outside the fermentation vessel such as humidity, temperature and altitude of the fermentation vessel.

40. A method of controlling a coffee fermentation process in one of a plurality of fermentation systems, the method comprising:

41. The method according to claim 40 wherein analysing the stored fermentation data sets includes obtaining a measure of the fit of the data relating to the particular fermentation system to data relating to one or more stored fermentation data sets and optimising the indication of the coffee grade among the fitted fermentation data sets.

42. A method for determining a predicted grading for a batch of processed coffee, the method comprising:

43. The method according to claim 42 wherein outputting one or more predicted grades comprises outputting a single predicted grade for the coffee.

44. The method according to claim 42 or 43 wherein outputting one or more predicted grades comprises outputting a grade data set for the coffee.

45. The method according to any of claims 42 to 44 wherein the grade data set includes at least one of an overall coffee grade, a grade relating to the coffee taste, aroma, acidity, finish, bitterness, body or flavour.

46. The method according to any of claims 42 to 45 wherein analysing the stored fermentation data sets includes obtaining a measure of the fit of the received fermentation data set to the plurality of previous fermentation data sets.

47. The method according to any of claims 42 to 46 wherein determining one or more closest-matching data sets comprises determining a plurality of fitted data sets and wherein outputting one or more grades comprises outputting a range of grades for the coffee.

48. The method according to any of claims 42 to 47 wherein outputting one or more grades comprises outputting a measure of the error associated with the grade determined in the analysis.

49. The method according to any of claims 40 to 48 wherein the fermentation data set includes data relating to the particular fermentation system or fermentation process that produced the fermentation data set, optionally including an identifier of a location of the particular fermentation system or an identifier of an operator of the particular fermentation system.

50. The method according to claim 49 wherein the data relating to the particular fermentation system includes data relating to the coffee bean being fermented in the fermentation system, optionally including coffee bean type, coffee bean origin and parameters relating to the pre-processing of the coffee bean.

51. The method according to claim 49 or 50 wherein the data relating to the particular fermentation system includes data relating to the conditions of the system, for example the altitude of the fermentation system, the temperature and/or humidity in the environment surrounding the system.

52. The method according to any of claims 40 to 51 wherein the plurality of process parameters includes a pH threshold value, a temperature threshold value and/or a dissolved oxygen level threshold value.

5

53. The method according to any of claims 40 to 52 wherein the fermentation data set includes sensor readings obtained from a plurality of sensors operating during the 'fermentation process.

Intellectual

Property

Office

Application No: GB 1703120.4 Examiner: Dr Caroline Bird