Coffee Cleaning & Blending:
The first step is thorough cleaning and removal of defective
beans, followed by blending of different types and size to
ensure best flavor.
Roasting & Grinding:
The second step is roasting through either batch or continuous roasters. Roasted coffee is reduced by grinding to suitable size.
The third step is extraction of ground coffee through a batch or continuous system either using a pressure vessel with hot
water or an alternate approach of counter-current column battery unit.
The extracted coffee liquor is passed through the aroma recovery plant. In the plant the volatile aroma is stripped off from the coffee before it enters the evaporator.
The fifth step is concentration of the extract through multieffect
evaporators with TVR system .
The sixth step is conversion of concentrate to instant coffee
powder by spray drying. Drying is done under controlled
conditions to protect and preserve aroma and flavor. Fludized
bed dryer is coupled with the system.
Spray dried powder then converted into soluble granules in
an agglomerator tower.
Freeze dryer retains aroma, improves appearance and taste
because freeze drying takes place at a low temperature which
minimizes heat damage and retains volatile components
(aroma). It also increases the shelf life of the dried product as
compared to standard drying practices. Freeze drying
involves dehydration of food products at low temperature
and pressure. As a result only the moisture is removed,
leaving the molecular structure intact. The end product is light
in weight with least or no change in volume. Worldwide
freeze-drying technology is considered as the ultimate
amongst all other dehydration methods. Hence this technique
is currently being used for the production of instant coffee.
Packing & Filling:
The Instant Coffee Powder is taken to the filling and packing
stage. For filling into tins or jars, vacuum operated filling
system is used. For filling into sachets, a form fill-sealing
machine is used. The filled containers / flexible packings are
then packed in the shipping cartons and sent for dispatch to
the finished goods warehouse.