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Instant CoffeeProcess technologies forthe instant coffee industry
2·Instant CoffeeTurning raw materials intofinished productsGreen Bean TreatmentRoastingSolutions for cleaning, blendingSolutions for batch mode orand storage using technologycontinuous operation andfrom selected partnersstorage using technologyfrom selected partnersExtractionBatch mode orcontinuous operationRoast Bean TreatmentGrinding and conditioning ofthe roasted productExtract TreatmentClarification, storageand aroma recoveryfrom the coffee extract
Instant CoffeeConcentrationLiquidsFreeze concentrationand evaporationSpray DryingComplete solutions forspray dried coffeeFreeze DryingComplete solutionsfor freeze driedcoffeeAgglomerationFor low dust powder andcustomized granulesCIP SystemPackingProcess ControlFast and flexible Clean-in-Place featuresPowder: Packed in bulk or retail quantitiesPlant supervision andLiquid: Supplied in cans or drumsmonitoring, recipe control,logging functionality·3
4·Instant CoffeeSolutions for high quality instantcoffee productionEvery day, all over the world, GEA’s comprehensive portfolioof expertise and technology optimize every stage of coffeeprocessing and ensure that consumers receive a superior product.GEA is a world leader in instant coffee technology. With decadesProven abilityof experience in this field, our expertise within spray and freezeWe have maintained our leading position by repeatedly provingdrying, evaporation and freeze concentration, extraction, extractour ability to provide reliable and innovative technical GEAtreatment, aroma preservation, agglomeration/granulation, andsolutions for the entire process from product testing to plantpowder handling and packing is unrivaled.installation and after sales support.So, whether the instant coffee is to be a granulate, a fine — orOur constant focus on providing cutting-edge quality to ourcoarse — powder or in liquid form, a GEA instant coffee plantcustomers is the main reason why we have installed more thanoffers the best solution. GEA equipment and process lines are200 GEA plants for the instant coffee industry worldwide.used by producers of instant coffee all over the world.A complete rangeAs a solutions provider, no one knows more about processingWe supply solutions for all aspects of successful coffeeinstant coffee than GEA. Our expertise and productionproduction, making us the obvious supplier of individual GEAtechnology, combined with our plant design knowledge andplant as well as complete lines. Our solutions include our ownengineering experience, deliver high quality product withunique GEA technologies as well as equipment from trusteddefined properties and strong natural flavors.partners in coffee bean handling, roasting, and packing of thefinished product.Our customers frequently benefit from higher product qualityand significant cost reductions owing to efficient wastetreatment and recycling systems.Furthermore, our commitment extends beyond the actualplant. A strong international network of companies gives ourcustomers the comfort of local service combined with the qualitythat comes from a global presence.
Instant CoffeeQuality engineering solutions at a glancePartnering for successWith data gathered from more than 80 years ofWe have the experience and know-how to ensureexperience and a reference list of some 10,000that every stage of your project is completed asinstallations, we’re perfectly equipped to engineersmoothly as possible, includingthe exact product you want from your coffee — and product testing at our test station in Denmarkthe processes needed to produce them. process evaluation and optimization design and engineeringOur coffee powder engineering specialists will project managementhelp you to design the ideal system for your needs plant delivery, installation and commissioning— including dedicated process control — that operator trainingmeets precise specifications. In addition, using our technical service and the supply of spare partsadvanced “gentle processing” technology, the coffee’s project financing.natural essence is retained, guaranteeing outstandingquality and flavor for your final product.Ultimately, our goal is to help you to stay ahead ofthe competition with superior product quality, highproductivity and high-yield processes.With market demands changing all the time,the coffee industry is dynamic. So, whether youCoffee cherryneed a new investment, process modification oroptimization, it’s all part of the GEA solution. Fromadvanced equipment to full integrated plant design,Pulpfrom feed formulation to competitive powders andMucolagefrom sanitation to safety, GEA has the answer.Green beanParchment hullSilverskinCoffee FactsCoffee beans are seeds from the fruit of the coffeebush. When roasted, the beans lose 15–20% oftheir weight, but increase up to 25% in size.·5
6·Instant Coffee
Instant CoffeeTechnology overviewExtractionP8-9Aroma recoveryP10EvaporationP10FREEZE CONCENTRATIONP11MicrogrindingP11Freeze DryingP12-13Spray Drying and AgglomerationP14-15Product handling and packingP16Pilot Plant and Test FacilitiesP17CIP and Process ControlP20Digital ServicesP21-22·7
8·Instant CoffeeInstant coffee extractionNo matter how you process your coffee beans and whatever theyield, aroma is key. For great-tasting coffee, the more of that aromayou can extract, contain and preserve, the better the final product.Time and temperature play a significant role in determining theFlexibility, high yield: CARINEquality of the aroma. Short extraction times at moderate/lowCompared with the FIC , the CARINE extraction plant istemperatures deliver high quality extracts.equipped with ten percolator columns. The two additionalcolumns operate at a higher temperature, 185–195 C, resulting inThe FIC provides a fast, turbulent water flow around the the highest possible yields of approximately 60%.coffee particles to enhance the extraction rate at the desiredtemperature. The CARINE, employing prolonged extractionAfter the high temperature treatment, the extract is cooledtimes and higher extraction temperatures, has been developedto approximately 160 C to avoid the formation of off-notes.for customers wishing to obtain the highest possible yields.Following the extraction (hydrolysis) process, the extract isharvested at a temperature of 140 C before cooling, and theDesigned for high performancefreshly roasted coffee is separated at moderate temperatures ofEliminating the need for manual operation, the compact andapproximately 130 C to obtain a high-quality aroma extract.fully automated FIC and CARINE ensure precision processing that meets the world’s highest standards. With an integratedIf required, the CARINE can also operate in FIC mode to obtainPC/PLC (Programmable Logic Controller) system, the FIC anda higher quality end product. As such, users have the optionCARINE offer easy operation and uniform extract quality.of maximizing yield or maximizing quality in FIC mode,depending on the requirement and application. For ultimateFurthermore, every FIC and CARINE component is designed flexibility, the CARINE is the plant of choice.to the highest manufacturing standards for efficient, long-lastingperformance.Key points: CARINE High yields Extremely versatile Can also operate in FIC mode High temperature operation High quality Process capacities of 125–1500 kg/h soluble solids
Instant CoffeeFast extraction, high quality: FIC CONTEX extraction solutionsThe highly efficient FIC delivers a high yield (upThe continuous countercurrent extraction processto 53%) with better quality attributes than otherhas been a focus of dedicated research andequipment. In addition, the FIC performs 50%development for many years at GEA, resulting in thefaster than conventional manual extraction methods.successful application of the technology to a wide range of coffee products.The fully automated, continuous FIC extractionsystem comprises eight percolator vessels thatWe now offer six standard plant sizes with volumesoperate in a flowing battery design. What’s more,of 27, 180, 300, 830, 1400 and 2750 L. Incorporatingthis highly flexible system can perform in a varietyfour extraction steps in one, this versatile yet robustof different modes for a wide range of coffee types.equipment offers short extraction times and higherquality extracts in a continuous process. EliminatingOperators can choose between one, two or all threethe need for a decanter and reducing the number ofmodes of operation — and easily change from oneconcentration stages means the process is more cost-mode to another — to create a finished product thateffective and efficient.meets the specific requirements of your market andapplication.Considering the best finished product starts with thebest extraction — and the best extraction is closelytied to extraction time — the FIC ensures you’realways up to speed. The FIC can do it all.Key points: FIC Three modes of operation Full- and pilot-scale plant available Fast extraction High quality Process capacities of 125–1500 kg/h·9
10·Instant CoffeeGentle liquid processing:extract treatmentWhereas other available systems involve working with the wholecoffee extract, the GEA process actually separates the good aromasfrom the bad ones, which results in a higher quality end product.Aroma recoveryEvaporation: extract concentrationTo prevent the loss of valuable aroma components duringAs the coffee extract is a thermally sensitive product, mildthermal concentration, the extract is stripped of its volatiles inprocessing conditions throughout the concentration step area flash evaporator. During evaporation, the flashed off aromaessential. Concentration by evaporation is an important andmixes with flashed off water. The combined mixture of aromahighly energy efficient dewatering step that maximizes the solidsvolatiles and water vapor is then further concentrated (up to 10content of the extract prior to freeze or spray drying. In our multi-times) using a distillation column. The resulting aroma distillatestage evaporators, the water is gently removed under vacuum atis recovered in a two-stage condenser system, kept cold andlow temperature keeping the original coffee extract taste.subsequently added back to the coffee concentrate prior to thefreeze or spray drying stage.GEA evaporators are designed to maintain all the parametersrequired to achieve the highest quality of the final product.Many of the functional properties of powders, such as solubility,heat stability and the WPNI index, are determined duringevaporation, and can only be achieved by carefully managing theheating and handling processes.The design of our evaporator systems ensures that the highestproduct quality is maintained with optimal energy efficiencywith extended operating cycles. They are equipped with eithermechanical vapor recompression (MVR) or thermal vaporrecompression (TVR) for this purpose. Our design fulfills ourcustomers’ highest requirements for technology, product quality,energy efficiency and environmental sustainability.ClarificationTo comply with international standards for convenient coffee,clarification is an essential part of the process. A systemconsisting of filters and centrifuges is used to separate insolubleparts from the extract.
Instant Coffee·MicrogrindingTo prevent the loss of valuable aroma components, themicrogrinding of roast coffee beans is done just before theconcentrated coffee extract is dried. This wet grindingtechnique operates at a low temperature so that it capturesand preserves both the flavor and aroma of the coffee bean,producing an even better tasting product and a uniquedrinking experience.It also increases both the overall yield of the coffee beans andthe capacity of the dryer. The GEA MicroWet grinding systemcan be integrated within an existing coffee line or work as aFreeze concentrationIn high end markets, wherein maximum quality retention is akey driver, freeze concentration provides an optimal solution forconcentrating coffee extracts.GEA’s IceCon freeze concentration system ensures gentle coffeeextract concentration without thermal impact on the productowing to its subzero processing temperatures. Moreover, aswater is converted into pure ice crystals and these are efficientlyseparated from the concentrate, there are no detectable aromalosses included in the separated ice.The system can run for weeks without cleaning and provideseasy and efficient operation. Freeze concentration is mosteffective for concentrating aroma-rich, high-quality extracts.Blending with evaporated hydrolysis will provide an extractthat’s suitable for spray or freeze drying.standalone system.11
12·Instant CoffeeFreeze drying for a premiumproductTo prepare the freshly concentrated coffee for freeze drying, itUsing our proven Structure Control System (SCS) for theis cooled, foamed and subsequently prefrozen. The prefrozenprefreezing and foaming process, product color, solubility andproduct is then pumped and fed to a belt freezer (continuous airbulk density can be controlled to meet any specific requirements.blast freezing) or a rota freezer to produce a solid phase (deepSubsequent freezing can be done using our Continuous Air Blastfrozen flakes), which is then granulated, sieved into desired(CAB) belt freezer or our Rota Drum freezer.granulate size and shape and automatically charged into trays.Granulating the frozen coffee slabs using a carefully designedThe filled trays leave the cold room and enter the vacuumsystem ensures the right granule size and distribution andlock of the freeze dryer. Here, they are stacked and conveyedoptimizes the process prior to freeze drying.horizontally through the different temperature sections of thedrying tunnel. Finally, the dried, granulated instant coffee leavesFreeze drying preserves all the desirable aspects of thethe freeze dryer through the outlet vacuum lock for furtherconcentrated coffee extract. The finished product commandsprocessing, such as oil spraying, metal detection and subsequenta premium price by meeting market demands for qualitypacking (bulk or directly into jars).parameters such as shape, size color, density and moisture.Benefits includeIdeal for both batch-based and continuous lines, our easy to use Fully continuous and automatic operation for the CONRAD solutionRAY and CONRAD units enable a unique degree of control overall of these crucial quality parameters and are designed to eliminate Automated color and density controlproduct loss, reduce energy costs and maximize plant reliability. Optimized energy consumption Integrated plant design2131 Foaming andprefreezing2 CAB freezing3 Granulation
Instant CoffeeCONRAD freeze dryers are ideally suited for largeOur RAY batch freeze dryers are used for smallervolume, high value products. The CONRAD rangecapacity requirements or as add-on units to existingis fully automated and requires only minimal staffcoffee processing plant. Designed as modular systemsfor continuous operation. All movement and processfor batch-based applications, RAY freeze dryers offerparameters are carefully controlled, monitored andseveral advantages during installation and operation,logged. Protecting all the qualities obtained in theand provide easy access for cleaning and maintenance. concentrate, a consistently first-class instant coffeeis produced thanks to the integrated entire-processcontrol system.A unique feature of all GEA freeze dryers is theinternal vapor condenser with a built-in deicingsystem. Compared with external condenser systems,the equipment is compact, uses up to 40% lessenergy, minimizes product loss to as little as 0.1%and, because the condenser system does not rely onRAY Freeze Dryerlarge external vacuum valves, it’s significantly moreRefrigerationreliable. In addition, they’re economical to operateAn absolute prerequisite at the freeze-drying stageand easy to maintain.is refrigeration, when precise temperature controlhelps to ensure that the instant coffee product retainsTo further optimize the productivity of theits key characteristics, as well as optimizing energyCONRAD , an ECO version is available; with a largerconsumption. Designed for any stage of instantdiameter and an increased condenser surface, thecoffee processing, our portfolio further encompassesrefrigeration system can be made up to 10% morewater chillers and industrial cold room refrigerationenergy efficient.solutions that can be tailored to match your specific application, plant layout and available space.5464 Freeze drying: tray going intothe Atlas CONRAD freeze dryer 5 Atlas CONRAD freeze dryer6 Freeze drying: tray withthe finished product·13
14·Instant CoffeeCost-effective spray dryingThe most economical way to produce soluble coffee is spray drying,which results in free-flowing and agglomerated/granulated powders.Thanks to a high level of control and GEA processOptimized for fast, effective cleaning and reducedknow-how, our customers can manufacture productsdowntime, our spray dryers offer gentle processingthat meet and exceed the demands of their individualand controlled drying conditions that preserve bothmarkets regarding bulk density, residual moisture,organoleptic and sensory properties. And, as everyflowability, color and solubility.application is different, our test centers are availableto help you develop and trial your new products andGEA offers two types of spray dryers for theprocesses.manufacture of spray-dried soluble coffee:NOZZLE TOWER (NT) spray dryers havetraditionally been used to produce free-flowingpowders comprising individual round, soluble beadswith an average particle size of 100–250 µm. Thetower-like chamber design allows for a long residencetime to dry the product in a single operation.Fluidized Spray Dryer, FSD : The most commontype of spray dryer used today, the compact FSD is equipped with an integrated fluid bed. To achievethe required moisture content and temperature,post-drying and cooling are done in an externalVIBRO-FLUIDIZER . FSD s produce a free-flowingagglomerated/granulated coffee powder withaverage agglomerate sizes of 100–300 µm. The lowertemperatures used during drying give improvedaroma properties.All our spray dryers conform to the highestindustry standards of hygiene, energy efficiencyand plant performance to ensure safe operationand maintenance. Control and automation softwarecontinually monitor and adjusts in-processparameters to meet the requirements of the recipeand ensure repeatability.GEA FSD Spray Dryer
Instant CoffeeREWET Agglomeration for large agglomeratesDifferent markets require different types of convenient solublecoffee. To meet the demand for granulated, dust-free products,the powder can be processed in a REWET AGGLOMERATOR (RWA). Material handling during the agglomeration processitself is controlled according to the desired properties of the endproduct (the average particle size is approximately 1400 µm).Powder producedon GEA NozzleToweRPowder producedon GEA FSD Powder producedon GEA REWETAGGLOMERATOR GEA REWET AGGLOMERATOR ·15
16·Instant CoffeeProduct handling and packingFollowing the main processing steps, powder handling and packingsystems from GEA ensure that the finished product is handled safelyand gently during storage, conveying and packing whilst ensuringcritical quality characteristics are retained.Powder handling and packing is an important part of the instantIn addition, GEA offers granulate sieving and conveying in coldcoffee production process as this is when the product is at itsroom environments at temperatures as low as –53 C. Freeze-most valuable and fragile. By bringing many unit operationsdried coffee prepared using a Continuous Air Blast (CAB) belttogether, plant and systems from GEA offer numerous benefits.freezer is transferred to a granulator and then to our sifters,elevators and conveyors. Finally, a tray filler is used to feed thePrecise dosing techniques ensure that the product is consistentlyCONRAD freeze dryer.uniform. For instance, a mounted feeder before the CONRAD freeze dryer guarantees that a defined amount of coffeeGEA’s precision dosing and sifting machinery enablesenters the equipment. An uneven layer would result in non-manufacturers to deliver a high-quality product. Plus, byhomogenous coloring and the batch would be discarded.incorporating vibration technology for conveying to otherprocessing steps, there is less chance of the coffee productAccurate sifting also has a role to play. A sifter makes sure thatsuffering from physical or aesthetic damage during production.the end product is uniform in size. Dust and oversized particlesare removed before packing, thereby giving the end product aGEA offers a range of solutions to fill coffee powders into bagsconsistent appearance.and boxes. From low capacity manual systems to automatedhigh volume lines, our machinery can be tailored to meetspecific production requirements where we focus on minimizingproduct loss or damage, thereby protecting product quality.GEA vibratory sifterFurthermore, vibratory technology provides gentle handling offragile products such as freeze-dried coffee during conveying,GEA bag-in-box filling systemsifting or dosing, contributing to the required “edgy” shapeIntegrated case erection, liner insertion, sealing and closingand preventing the granules from becoming worn down andsystems can also be included to provide a complete solution for“rounded.”filling and handling. At the end of the line, we can also providecase handling, labeling and palletizing for a turnkey process.
Instant CoffeePilot plant and test facilitiesGEA test facilities help you to achieve greater confidence in the safeand repeatable production of your instant coffee products prior tomarket release.To minimize product development risk, GEA’s center ofThe RAY PP offers the following economic and technicalexcellence in Copenhagen, Denmark, offers customers accessadvantages:to laboratory and pilot plant facilities and a wide range gentle heat treatmentof equipment to try out new recipes and work on process preservation of product structure and size, as well as keyoptimization and validation before investing in industrialscale machinery.attributes such as color and nutrients stable products with a long shelf-life high throughput and large capacity condenserTalk to us at GEA to test out our equipment for extraction, continuous deicingaroma recovery, freeze concentration, freeze drying, spray CIP-compatible hygienic design.drying and agglomeration. With our state-of-the-art aromamanagement equipment, we can help you to monitor 50 ofFIC and CARINE Pilot Plantthe most valuable aromas to optimize the quality of yourDepending of the desired yield and quality, the versatileproduct for the end-user.FIC and CARINE Pilot Plant are designed to operate inthree standard modes: dual-dual, dual-split and single-split.RAY Pilot Plant (PP) Freeze DryerWith a processing capacity of 5–7 kg/h of roasted andOperated via a touchscreen, the RAY PP is designed forground coffee, fast, batch-wise extraction is achieved usinghygienic processing and, as such, is easy to clean andeight to ten columns (seven to nine in production mode andmaintain. Once product has been placed in the chamber, theone in service mode).process runs fully automatically and all vital parameters aremonitored and stored to provide full documentation andThe Pilot Plant uses a very efficient, high-speed, doubleensure repeatability.extraction process, which means that the aroma compoundscan be separated in as little as 15–20 minutes. The resultingAlthough designed to operate at 0.2 mbar, the RAY 1 canaroma extract is of extremely high quality. Customertolerate pressures as low as 0.1 mbar. In addition, the RAYbenefits include the ability to exercise hot and cold brewconcept ensures short downtimes between batches, basedconditions, and run high yield CARINE-extractions.on rapid evacuation times, effective deicing and efficienttray loading.FIC Pilot Plant·17
18·Instant CoffeeMore than just a plantPlant sizesGeneral operational data for GEA Instant Coffee (IC) plant isgiven in the table below. Available sizes refer to the amount ofkg that is produced each hour; for example, an IC-250 plant willproduce 250 kg of instant coffee each C-1500Green coffee input(kg/h) 10% 002640-36003300-4500Roasted, ground coffee(kg/h) 6% 02300-31202875-3900*Yield % FIC -59.5Instant coffee(kg/h) 3% H2O125250330550750100012001500Annual production (t/year)Based on: 7500 (h/year)94018752475412556257500900011250Typical sizes*Yield % CARINE Extractor*Yield is a result of the type and mix of beans. Robusta will typically give a higher yield than Arabica.
Instant CoffeeSustainabilityEnvironmental protection and sustainability haveThe use of heat pump technology in certain processbecome an essential part of any production process.steps can significantly reduce the need for non-In the instant coffee business, these conceptsrenewable energy sources and provide tangiblehave now come into sharp focus and consumersdeliverables. We supply technology and applicationincreasingly demand processes that do not damagesolution packages that ensure measurable benefitsthe environment or waste the Earth’s naturalwith a short payback time.resources.Consistent product quality reduces waste and theAs more and more organizations elect to follow theneed to rework product, reduced emissions savesUN Sustainable Development Goals, they’redisposal costs and helps to protect the world’sincreasingly relying on GEA’s extensive know-howecosystem, and the clever use of energy reducesand technical insights to tackle climate change andutility expenditure and preserves fossil fuels.preserve our oceans and forests.By combining the strengths and process knowledgeGEA works continuously to refine its equipmentin applications such as freeze drying, refrigerationand processes, leading the way in sustainability andand heating for Sustainable Energy Solutionshelping its customers to build tomorrow’s plant(SEnS), separation, filtration and digital solutions/today. Key focus areas in the coffee productioncapabilities, our unique insights ensure operationalsector include decreasing both energy and chemicalexcellence, cost benefits and environmentalconsumption, and the reduction of wastewater andresponsibility.water usage by recycling and reuse.·19
20·Instant CoffeeClean-in-Place (CIP) andprocess controlControlling and monitoring a process line is an absoluteInstrument and system specifications are selected inprerequisite for any operator. GEA’s proven process controlco-operation with our customers to ensure the best hardwaresystem meets all requirements for safety, flexibility, hygieneservice during the lifetime of the plant. Cleaning, albeitand ease of use.necessary, can be an expensive and time-consuming part of theprocess. Drawing on more than 80 years of work experienceUsing standard hardware components, the process systemwith sanitary processes, GEA has developed a series of Clean-in-enables you toPlace (CIP) systems. supervise and monitor automatic plant start-up, shutdown andcleaning proceduresWith features such as retractable nozzles in the main drying work with several product recipes in one systemchamber, as well as highly efficient process water recovery, log every process activity for real-time and historical trending.the GEA CIP system makes a significant contribution to theprofitability of the entire process line.
Instant Coffee·21Advanced process optimizationIncreased process stability and optimum performancefrom your instant coffee production line with GEA OptiPartnerGEA expertise helps you to get optimum performance fromFocusing on productivityyour instant coffee production line. GEA OptiPartner is aWe focus on improving your productivity by providing digitaldigital software solution that combines GEA’s process designoptimization modules for evaporation, foaming, CAB freezing,and operational know-how to optimize process and productiongranulation and freeze-drying process units. For example, inlines. Using digital technologies, such as advanced machinefreeze drying, our customized analytic algorithms providelearning algorithms, GEA OptiPartner increases the efficiencyreal-time optimization of residual moisture content on the finaland productivity by reading the process data, applying real-product. Similarly, the granulation module enables real-timetime analytics, identifying the optimum operation point atreduction of fines flow and prediction of blocking conditions ina given process state, and generating new set-points leadingthe freezing process.to that point. In other words, GEA OptiPartner acts as an“autopilot” on top of the existing control system.The various GEA OptiPartner modules are delivered all theway from development and implementation to support andBenefits at a glancemaintenance, for a yearly subscription. Process stability improvement Increasing plant availability Improving all key performance indicators Reducing the impact of variable operator skills Fail-safe operation even with semi-skilled staffRaw material qualityvariations and weatherconditions are main sourcesAdvanced algorithms analyzedata and take controldesicions consistentlyHigher plant availability andbetter operator utilization inother plant-wide tasksIncreased yield, with directand indirect financial impact
22·Instant CoffeeReal-time assistance, anywherein the worldBe on-site when you’re off-site with GEA Remote Eye WearSpecifically designed to enhance communication and providereal-time connectivity, GEA Remote Eye Wear offers an instanton-job sup
Instant coffee extraction Time and temperature play a significant role in determining the quality of the aroma. Short extraction times at moderate/low temperatures deliver high quality extracts. The FIC provides a fast, turbulent water flow around the coffee particles t
