IE83731B1 - A batch process for coffee production - Google Patents
A batch process for coffee production Download PDFInfo
- Publication number
- IE83731B1 IE83731B1 IE2002/0356A IE20020356A IE83731B1 IE 83731 B1 IE83731 B1 IE 83731B1 IE 2002/0356 A IE2002/0356 A IE 2002/0356A IE 20020356 A IE20020356 A IE 20020356A IE 83731 B1 IE83731 B1 IE 83731B1
- Authority
- IE
- Ireland
- Prior art keywords
- coffee beans
- beans
- roasting
- coffee
- chamber
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 238000010923 batch production Methods 0.000 title claims description 5
- 241000533293 Sesbania emerus Species 0.000 claims description 64
- 240000005158 Phaseolus vulgaris Species 0.000 claims description 38
- 235000010627 Phaseolus vulgaris Nutrition 0.000 claims description 32
- 238000003860 storage Methods 0.000 claims description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 17
- 239000000567 combustion gas Substances 0.000 claims description 16
- 238000000034 method Methods 0.000 claims description 15
- 241001438449 Silo Species 0.000 claims description 14
- 238000001816 cooling Methods 0.000 claims description 12
- 239000007789 gas Substances 0.000 claims description 7
- 238000000227 grinding Methods 0.000 claims description 6
- 238000005507 spraying Methods 0.000 claims description 6
- 238000007599 discharging Methods 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 5
- 239000007921 spray Substances 0.000 claims description 5
- 238000002485 combustion reaction Methods 0.000 claims description 4
- 230000001186 cumulative Effects 0.000 claims description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 4
- 238000005303 weighing Methods 0.000 claims description 4
- 238000005070 sampling Methods 0.000 claims description 3
- 229910052757 nitrogen Inorganic materials 0.000 claims description 2
- 229950008597 drug INN Drugs 0.000 abstract 1
- 239000003570 air Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 210000003491 Skin Anatomy 0.000 description 6
- 235000021331 green beans Nutrition 0.000 description 5
- 238000004806 packaging method and process Methods 0.000 description 4
- 238000011068 load Methods 0.000 description 3
- 239000000428 dust Substances 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000000796 flavoring agent Substances 0.000 description 1
- 235000019634 flavors Nutrition 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000000717 retained Effects 0.000 description 1
Abstract
ABSTRACT dk\hornedbkrnayO2\m3a25-1opecapr22 tE02"“‘ /i'I‘,‘| 'Wt:Jr'fi > K /cn*:fi’W%F1 -fillF'w'="-idgll u :- « ~uIIs+f'«f-zfln a u- ~ "='lJEv'_«“:?3%v"'-'_~F|v"-if] L" U- -£1l.l.TT.".""" [I I'J- %l3~ ""U%U“ -an no mg? " «unwnu T < ~r—wI1r-"~*%~.“-'—"::«f«'f={1uuc» u H «an n + lE02o35s A/8 'E"?°356 To Fig 5 89 E r-v89 % ;E'._[l_£-EELLIS4 — ~::nB=I=3n:. — Ema:-.':=In3 - ~3n%n3 - 5/8 'E"-’'’355 'E97_fl35s 6/8 ® ~ =s-.::=.:- LE 6‘ mm‘ [Inn :5: 4—i ;_.I1nn ” DIW- \/\/'\/‘(/\/\ 'EU20355 ELQ-_8
Description
A batch process for coffee production
Introduction
The production of coffee is becoming more difficult due to the increasing
sophistication of the consumer's taste and a need to thus control, more tightly, the
production process and to ensure that there are less variations between the end
products or batches produced. A further problem is that additionally the consumer is
becoming more concerned about the appearance of, for example, unground coffee
beans, rather than just s'mply the organoleptic properties of the coffee. Further, as
the price of the raw material increases, it becomes more important for the
manufacturer or blender of the coffee to ensure that the correct blends are achieved at
minimal cost. It is becoming vtal to control production costs and to ensure adequate
quality control so that the product is not rejected due to failing the stringent tests of
both taste and appearance. Every batch of coffee that has to be discarded represents
a direct loss, not alone of raw materials, but of the processing costs to the blender or
manufacturer.
Our UK Patent No. 2282046B discloses a coffee production process and the present
invention is directed towards improvements in this process.
One of the major problems is to ensure that there is adequate and uniform roasting of
the coffee beans. This has been done generally by providing some device to ensure
that the coffee beans are sufficiently agitated in the roasting drum to ensure that they
are subjected to adequate heat. The problem is that with many conventional roasting
drums, even with the coffee beans agitated considerably by agitating blades,
adequate roasting has not been achieved.
The problem with excessive agitation of the coffee beans is that, while adequate
heat distribution is achieved, the skin of the beans often splits and is removed,
leaving a residue which in turn gets overheated This chaff then tends to remain in
the heating drum where it is furtherbheated and roasted leading to an unpleasant
taste when it is eventually discharged with another batch of the roasted coffee
beans.
The provision of adequate and uniform roasting is very complex. It is not just simply
a matter of agitating the beans as much as possible while applying heat It is
necessary to ensure that while the beans are adequately agitated and uniform heat
is supplied, the beans do not split There must not be excessive heating of the
exterior of the beans which will cause the beans to split with consequent removal of
the skins and the formation of chaff.
European Patent Specification No. O359515A (NGK Insulators Ltd.) describes in
some detail, the various problems in relation to coffee bean roasting and further
discloses a device to provide a uniform roasting of coffee beans. Again, itconsists
of the two elements of trying to provide uniform heating of the beans while agitating
the beans.
It is also known to spray the roasted coffee beans with water immediately after the
roasting has been completed within the roasting drum. As a resut of the spray of
water onto the coffee beans in the roasting drum, the temperature of the coffee
beans falls sharply. This is generally done to ensure that the coffee beans are
roasted to the correct temperature and not over-roasted. Essentially, this spraying
with water is a pre-cooling, either carried out'immediately after the roasted beans
leave the roasting drum or in the roasting drum prior to discharge therefrom. A
typical system is that disclosed in German Patent Specification DE 4028111A1
(Tchibo Frisch-Rdst-Kaffee GmbH) where, after roasting but without moistening and
cooling taking place in the roasting drum, the roasted coffee is treated in a separate
moistening and cooling system.
Statements of Invention
According to the invention, there is provided a batch process for the production of
coffee comprising the steps of:-
sampling supply batches of green coffee beans and delivering
acceptable batches of green coffee beans to associated storage silos;
selectively discharging pre-determined quantities of between two and
five different types of green coffee beans from the storage silos into a
cumulative weigher, weighing each quantity of green coffee beans
delivered to the weigher in turn to produce a predesired batch of
mixed green coffee beans;
delivering the coffee beans into a roasting chamber, agitating the
beans by continuously raising the beans from the bottom of the
chamber to the top, delivering hot combustion gases into the chamber
through separate inlets, one delivering the gases tangentially to the
movement of the coffee beans in the chamber and the other at
substantially right angles thereto , the combustion gases being
maintained between 300°C and 650°C;
after the coffee beans have been roasting for some time, delivering a
continuous spray of water onto the roasting beans and continuing the
roasting;
stopping the roasting after a preset time;
discharging the coffee beans;
cooling the coffee beans by air;
then testing the batch of roasted coffee beans for colourand taste and,
if acceptable, delivering the coffee beans for one of a whole coffee
bean blending operation and a coffee blending and grinding operation;
packing the coffee by weighing, evacuating air and introducing
nitrogen.
A major advantage of the present invention is that by directing the hot combustion
gases into the chamber, through separate inlets which direct the gases both
tangentially and orthogonally to the wall of the chamber, adequate mixing of the
combustion gases is quickly achieved as the beans are being tossed and agitated
within the roasting chamber. This substantially reduces the roasting time. Further,
adding of water before roasting has completed ensures that the coffee beans are not
split because the water, when added, will coat the exterior surface or skin of the coffee
bean to ensure that they do not split as the skins will absorb some of this water. This
further improves the organoleptic properties of the coffee beans. Effectively, what is
done is to add back moisture to the coffee beans which is very advantageous.
Prior to discharging the roasted beans, further precooling by additional water
spraying can be carried out.
In one embodiment of the invention, the continuous spraying of water is carried out for
between 7.5 and 20% of the total roasting time and generally this is approximately
%.
In one process according to the invention, the combustion gases are heated to one
temperature, then the temperature is reduced, and finally, the temperature is
increased again, in each case the temperature being with'n the range specified.
In a further embodiment, the final temperature is greater than the initial temperature.
Typically, roasting is carried out for between 300 and 475 seconds. However, more
often, it is carried out for between 350 and 475 seconds.
Ideally, the pre-cooling of the coffee beans is carried out for between 200 and 350
seconds.
Preferably, the combustion gases are heated to between 325 and 675°C.
In one embodiment of the invention, the agitation of the coffee bean is carried out by
rotating a paddle wheel vigorously in the combustion chamber so that the coffee
beans are carried up the combustion chamber and then thrown down across the path
of the incoming gases.
Detailed Description of the lnvattion
The invention will be more clearly understood from the following description of an
embodiment thereof, given by way of example only, with reference to the
accompanying drawings, in which:-
Fig. 1 is a diagrammatic view of the plant according to the invention,
Figs. 2 to 7 are successive enlarged views of Fig. 1 from a left to right, and
Fig. 8 is a perspective view of a roaster according to the invention.
Referring to the drawings, there is illustrated batch process machinery for the
production of coffee, indicated generally by the reference numeral 1, comprising an
infeed station 2, a roasting station 3, an intermediate storage station 4, a grinding and
packing station 5, a coffee storage station 6 and a ground coffee packing station 7.
Referring now to Fig. 2, the infeed station 2 comprises an inlet hopper 10 for bags of
coffee beans which is connected to an airlock 11 and is fed to a weigher 12 by means
of a pneumatic conveyor 80. The weigher 12 delivers he beans to an intermediate
storage bin 13 which feeds, by a bucket conveyor 81, twenty two storage silos 16,
each of which is in turn connected to a cumulative weighs 17 feeding one of two
roasters (illustrated in Fig. 3) by a pneumatic conveyor 82. A dust extraction unit 15 is
connected to the intermediate storage bin 13. A roasted coffee bean storage silo 18 is
also illustrated which is fed by conveyors 84 from the roasters. A return pneumatic
conveyor 82(a) connects the silo 18 to the intermediate storage station 4 (Fig. 4).
Referring to Fig. 3, which shows the roasting station, the cumulative weigher 17 if Fig.
2 is illustrated feeding one of two roasters, indicated generally by the reference
numerals 19 and 20 by means of the pneumatic conveyor 82. The roaster 19 is
similar to the roaster described in UK Patent Specification No. 2282046 and requires
no further description. The other roaster 20 comprises an infeed hopper 21 feeding a
charging duct 22 which in turn feeds to an air extract duct 23 which is also fed by a
catalyser 24. The roaster includes a roasting drum 25 in which is mounted an axially
directed burner 26 and a tangentially directed burner 27. Mounted within the drum 25
is a mechanism of revolving paddles 37 mounted on radial arms 38 which are driven
by a motor (not shown). A discharge door 28 connects the drum 25 to a cowlhg 33
above a cooling chamber 29. Means to deliver cooling air through the cooler 29 and
also means to deliver water into the roasting drum 25 by a spray bar 30, mounted in it.
The cooling chamber 29 connects directly to a destoner bucker 32 via a vibrating
tray 31 and hopper 32 which is connected via a pneumatic conveyor 85 to a
collection hopper 35 which feeds directly a check weigher 36. The roasters 19 and 20
are either connected via the pneumatic conveyor 82a to the storage silo 18, illustrated
in Fig. 2, or are delivered via a pneumatic conveyor 87 to the intermediate storage
station, illustrated in Fig. 4.
Referring to Fig. 4, there is illustrated the intermediate storage station 4 for roasted
coffee beans from the roasters 19 and 20 and even the silo 18. This comprises
storage bins 40, for coffee beans delivered from the roaster 19 and20 for subsequent
grinding and storage bins 41 for delivery of coffee beans again from the roasters 19
and 20 which are not for grinding The storage bins 40 feed a pneumatic conveyor
and the storage bins 41 feed a pneumatic conveyor 89.
Referring now to Fig. 5, the storage bins 41 are connectedby the pneumatic conveyor
89 through a proportioning weigher 51 and a bucket elevator 52 to awhole bean
packaging machine 53 feeding an outlet conveyor 54. The bins 40 are connected by
the pneumatic conveyor 89 to grinders 55, each of which in turn feeds through screw
augers 56, silos 61 and 62 (see Fig. 6). All of the screw augers 56 are not shown.
Referring to Fig. 6, the silos 61 and 62 each have degassing ducts 63 and in turn feed
six packaging machines 71, shown in Fig. 7.
In operation, the production process comprises accepting batches of green coffee
beans which are sampled and tested at the infeed station 2 and, if acceptable, are
delivered to one of the storage silos 16 through the various weigher 12 and
intermediate bin 13 after cleaning bythe dust extraction unit 15 The green beans are
taken out of the storage silos 16 hrough the weigher 17 and by the pneumatic
conveyor 82 to one of the two roasters 19 or 20. With the roaster 19, the green coffee
beans are delivered through the infeed hopper 21 through the charging duct 22 in a
batch, usually of 120 kilos, into he drum 25. The burner 26 delivers hot combustion
gases and air axially into the drum 25, while the burner 27 delivers the hot combustion
gases and air tangentially around the drum 25.
As the green beans are delivered through the charging duct 22, the paddles 37 are
rotated causing the green beans to be delivered around the drum 25 and tossed up
into the axial and tangentially charging hot combustion gases thus roasting the
beans. When most of the roasting has taken place. namely, when most of tie
moisture has been extracted from the coffee beans and the outer skin of the coffee
beans is starting to change colour, usually somewhere between 20% and 7.5% from
the end of the cycle and generally at about 10%, water is sprayed on the still roasting
coffee beans. The beans thus absorb a certain amount of moisture and he skins of
the beans will not crack. This effectively seals the outer layer of the beans. Further
water may optionally be sprayed on the beans, while still in the roaster when the
roasting has stopped. This provides further pre-cooling of the beans prior to
discharge. Then, the roasted beans are delivered out the discharge door 28 into the
cooling chamber 29 where ambient air is driven up through the cooling chamber 29 to
further cool the beans which are delivered out the vibrating tray 31 through the de-
stoner 32, collection hopper 35 and check weigher 36 to one or other of the sets of
bins 40 or 41 for storage.
Generally, the batch of beans that is roasted will be predesired and determined
quantities of between two and five different types of green bean from the storage silos
16. The cooled roasted coffee beans are retained in the storage bins 40 or 41, either
for subsequent grinding and packaging or for packaging as whole beans. At various
stages during the operation, particularly prior to accepting the green beans and also
after roasting, the beans are tested for taste and colour since colour is very important
in the final package of either ground or whole roasted coffee beans.
Generally, the batch of green beans is released into the roaster 20 in batches of 120 I
Kg. They are generally roasted over three heating stages at preset temperatures fora
desired period of time. It is these differences in parameters that determine the final
colour and flavour of the roasted coffee.
The following table shows the loading of the various burners and the temperatures
achieved for a typical batch. The percentage loading refers to the amount of
additional air that is added to the burners to control the temperature.
Table 1 — Typical Burner Temperatures
Axial Tangential Tangential Axial
Heating Gas Heating Gas
Full Load 068% 050% 467°C 342°C
* Reduction 055% 035% 525°C 499°C
2"“ Reduction 040% 025% 505°C 469°C
Nonnally, the roasting takes place at any time between 300 and 475 seconds. It has
been found that with the increased temperature and changes in operation, this is
sufficient. A typical roasting cycle is given in Table 2 below.
Table 2 — Typical Roasting Cycle
Time Seconds
Start
Most of moisture drawn off
350 Water in
Roasting ceases
It will also be noted from the above that the combustion gases are heated. generally to
between 300°C and 650°C but that the combustion gases are heated to one
temperature within the range specified and then, in a three stage process, the
temperature is then reduced and then the temperature is raised again. It has been
found that this provides the best quality coffee.
It has also been found that delivering the combustion gases both axially and
tangentially together with vigorous agitation of the green coffee beans within the
roaster is vital to obtain the desired quality.
A particular advantage of the present invention is that oneis able to obtain the same
quality of final roasted beans in a cycle of between 5.5 and 6 minutes, while with more
conventional roasters, the cycle time is closer to 10 minutes. Further, the invention
allows a broad range of roasts to be provided. Additionally, it should be noted that the
axial heating produces the major amount of heat.
In the specification the terms “comprise, comprises, comprised and comprising” or any
variation thereof and the terms ‘'include, includes, included and including" or any
variation thereof are considered to be totally interchangeable and they should all be
afforded the widest possible interpretation.
The invention is not limited to the embodiments hereinbefore described but may be
varied in both construction and detail.
Claims (1)
1. A batch process for the production of coffee comprising the steps ofe sampling supply batches of green coffee beans and delivering acceptable batches of green coffee beans to associated storage silos; selectively discharging pre-determined quantities of between two and five different types of green coffee beans from the storage silos into a cumulative weigher, weighing each quantity of green coffee beans delivered to the weigher in turn to produce a predesired batch of mixed green coffee beans; delivering the coffee beans into a roasting chamber, agitating the beans by continuously raising the beans from the bottom of the chamber to the top, delivering hot combustion gases into the chamber through separate inlets, one delivering the gases tangentially to the movement of the coffee beans in the chamber and the other at substantially right angles thereto , the combustion gases being maintained between 300°C and 650°C; after the coffee beans have been roasting for some time, delivering a continuous spray of water onto the roasting beans and continuing the ‘ roasting; stopping the roasting after a preset time; discharging the coffee beans; cooling the coffee beans by air; then testing the batch of roasted coffee beans for colour and taste and, if acceptable, delivering the coffee beans for one of a whole coffee bean blending operation and a coffee blending and grinding operation; and packing the coffee by weighing, evacuating air and introducing nitrogen. A process as claimed in claim 1, in which the continuous spraying of water is carried out for between 7.5 and 20% of the total roasting time. A process as claimed in claim 1, in which the continuous spraying of water is carried out for approximately 10% of the total roasting time. A process as claimed in any preceding claim, comprising precooling the coffee beans by further spraying the coffee beans with water before the beans are discharged out of the roasting chamber. A process as claimed in any preceding claim, in which the combustion gases are heated to one temperature, then the temperature is reduced, and finally, the temperature is increased again, in each case the temperature being with the range specified. A process as claimed in claim 5, in which the final temperature is greater than the initial temperature. A process as claimed in any preceding claim, in_ which the roasting is carried out for between 300 and 475 seconds. A process as claimed in claim 7, in which the roasting is carried out for between 350 and 475 seconds. A process as claimed in any preceding claim, in which the precooling of the coffee beans is carried out for between 200 and 350 seconds. A process as claimed in any preceding claim, in which the combustion gases are heated to between 325°C and 675°C. A process as claimed in any preceding claim, in which the agitation of the coffee bean is carried out by rotating a paddle wheel vigorously in the combustion chamber so that the coffee beans are carried up the combustion chamber and then thrown down across the path of the incoming gases. A process substantially as described herein with reference to and as illustrated in the accompanying drawings. Coffee beans produced in accordance with the process of any preceding claim.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IE2002/0356A IE83731B1 (en) | 2002-04-30 | A batch process for coffee production |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IE2002/0356A IE83731B1 (en) | 2002-04-30 | A batch process for coffee production |
Publications (2)
Publication Number | Publication Date |
---|---|
IE20020356A1 IE20020356A1 (en) | 2003-11-12 |
IE83731B1 true IE83731B1 (en) | 2004-12-30 |
Family
ID=
Similar Documents
Publication | Publication Date | Title |
---|---|---|
AU698668B2 (en) | Process for cooking cereal grains | |
US4214376A (en) | Process and apparatus for the continuous drying and/or granulating of loose material | |
KR102111866B1 (en) | Seasoned meat manufacturing system including the Smart Stirring part and the seasoned meat produced by using it | |
JP6727528B2 (en) | Green tea production line and hybrid line equipped with green tea production line | |
US5664489A (en) | Food breading apparatus | |
IE49492B1 (en) | Treating calcined gypsum | |
KR920008847B1 (en) | System for manufacturing soybean powder | |
Kamphuis | Production of cocoa mass, cocoa butter and cocoa powder | |
US6000320A (en) | Food breading apparatus | |
Kamphuis | Production and quality standards of cocoa mass, cocoa butter and cocoa powder | |
IE83731B1 (en) | A batch process for coffee production | |
GB2388763A (en) | Coffee production | |
US2884327A (en) | Method of processing wheat | |
IES20020355A2 (en) | A batch process for coffee production | |
IE20020356A1 (en) | A batch process for coffee production | |
KR102532193B1 (en) | Chili Powder Manufacturing System | |
RU2728603C1 (en) | Production line for production of complete feedstuffs | |
US3271162A (en) | Process for segregating lupulin from dried hops | |
IES20000695A2 (en) | A coffee manufacturing process | |
US526256A (en) | William onderdonk | |
WO2003096853A1 (en) | A machine and method for treating edible material | |
GB2282046A (en) | A coffee production process | |
CN214250455U (en) | Rice air-drying device | |
JPH05261021A (en) | Seasoning mixing device for steam-boiled grain | |
CN220844167U (en) | Malt crushing, feeding and carding machine |