INSTANT COFFEE [SPRAY DRIED AND AGGLOMERATED]

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Instant Coffee

Instant coffee also known as soluble coffee is the dried water extract of roasted ground coffee. The product consists of brown colored, free flowing particles of uniform size. Most commercial products contain 100% pure “Coffee soluble solids”. Instant coffee was included in the army rations during the Civil War and has been available in various forms, for a hundred years. However, it was not until after World War II that instant coffee became a popular consumer item. Its product quality is to better method, of manufacture as well as trend towards the use of convenience foods. Sale of soluble coffee has leveled off since 1961 but prior to 1961 there was a fivefold growth over ten years. However, coffee has been a widely accepted society’s beverage for many. The habit of drinking coffee spread rapidly across Europe, especially coffee become known in Vienna. Later its culture spread thoroughly in several countries in South America Central America. West Indies, Ceylon and Western Africa.

Instant coffee also known as soluble coffee is made up of soluble coffee solids and is completely soluble in water. It is prepared by a process involving the use of percolation with water to extract the ground coffee. The solution is then dried by one of several methods:

1. In Spray Drying the extract liquid is traced through coffee nozzles into a stream of hot air or inert gases, the result of which is almost instantaneous drying. The dried material cobalt in a suitable chamber.

2. Vacuum drying, on a moving belt yields a dried product in the form of flakes which are very soluble even in cold water.

3. Freeze drying, depends on the removal of water by evaporation in a high vacuum and at very low temperatures. The method yields a product which is closer to brewed coffee than the others, but it is expensive to produce. The larger amount of instant coffee is produced by spray drying.

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Description

INTRODUCTION
INSTANT COFFEE
USES AND APPLICATIONS
RAW MATERIALS FOR COFFEE
COFFEE PROCESSING
COMPOSITION OF THE COFFEE
B.I.S. SPECIFICATIONS
MARKET OVERVIEW OF INSTANT COFFEE
GLOBAL INSTANT COFFEE MARKET OVERVIEW
COFFEE SECTOR IN INDIA
THE COFFEE PRODUCTION STATES
NESTLE’S MARQUEE BRAND HAS MAINTAINED ITS LEADERSHIP
IN THE INSTANT COFFEE MARKET
BRANDED COFFEE MARKET IN INDIA
THE COFFEE TRADE: RETAIL MARKET CONSTRUCT
HUL PIPS NESTLE IN INSTANT COFFEE
PRESENT MANUFACTURERS OF INSTANT TEA AND COFFEE PREMIX
PRESENT MANUFACTURERS OF INSTANT TEA
SPRAY DRYING
ADVANTAGE OF INSTANT COFFEE
CLASSIFICATION OF INSTANT COFFEE POWDER
NON-AGGLOMERATED INSTANT COFFEE POWDER
AGGLOMERATED INSTANT COFFEE POWDER
GRANULATED INSTANT COFFEE POWDER
CURING OF COFFEE BEANS
PRODUCTION METHOD OF INSTANT COFFEE
TABLE: YIELD (ON DRY BASIS) OF SOLUBLE SOLIDS FROM
ROASTED COFFEE
MANUFACTURING TECHNIQUE OF INSTANT COFFEE
FIG: FLOW CHART FOR PREPARATION OF AROMATIZED COFFEE
DRYING TECHNIQUES
SPRAY DRYING
NOZZLE TOWER SPRAY DRYER
FLUIDIZED SPRAY DRYER
FILTERMAT SPRAY DRYER
AGGLOMERATED POWDER
SEQUENCES IN INSTANT COFFEE MANUFACTURE
ROASTING
GRINDING
EXTRACTION
HOT CELLS
COLD CELLS
CONCENTRATION
THERE THREE METHODS
VACUUM EVAPORATION
CENTRIFUGATION
FREEZE CONCENTRATION
DEHYDRATION
METHOD OF PRODUCING INSTANT COFFEE
FREEZE DRYING METHOD
SPRAY DRYING METHOD
PACKAGING
MANUFACTURING PROCESS OF INSTANT COFFEE
BLENDS:
ROASTING:
GRINDING:
EXTRACTION:
THE FACTORS INFLUENCING EXTRACTION EFFICIENCY
AND PRODUCT QUALITY ARE:
DRYING:-
THE FOLLOWING FACTORS ARE IMPORTANT CRITERIA FOR
GOOD INSTANT COFFEE DRYING PROCESSES.
THERE ARE FOLLOWING TWO PROCESSES FOR DRYING
THE INSTANT COFFEE.
1. SPRAY DRYING:-
2. FREEZE DRYING:-
PACKAGING:-
ROASTED COFFEE:-
INSTANT COFFEE PLANT PROCESSING DETAILS
1. CLEANING & BLENDING OF GREEN COFFEE
GREEN COFFEE CLEANING
2. ROASTING & GRINDING OF GREEN COFFEE
COFFEE ROASTING CUM GRINDING UNIT
3. COFFEE EXTRACTION SYSTEM
COFFEE EXTRACTION
4. CLARIFICATION SYSTEM
CLARIFICATION UNIT
5. AROMA RECOVERY CUM CONCENTRATION SYSTEM (ARC SYSTEM)
AROMA RECOVERY UNIT
6. COFFEE CONCENTRATION
EVAPORATION SECTION – PART 2 CALANDRM SECTION
7. SPRAY DRYING SYSTEM
SPRAY DRYING SECTION
8. AGGLOMERATION SYSTEM
AGGLOMERATION SECTION
9. PACKING & FILLING
PROCESS FLOW DIAGRAM OF INSTANT COFFEE
FORMULATION OF INSTANT COFFEE (PREMIX)
INSTANT COFFEE PREMIXED WITH MILK AND SUGAR
PROCESS FLOW SHEET FOR INSTANT COFFEE PREMIX
POLLUTION CONTROL IN COFFEE PROCESSING INDUSTRY
CHARACTERIZATION OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
TABLE: EFFLUENT STANDARDS-SUGGESTED RANGE FOR POLLUTANTS DISCHARGE INTO INLAND SURFACE WATERS
SOURCES OF WASTEWATER:
FIG: WATER BALANCE DIAGRAM
ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE
PROCESSING INDUSTRY:
COFFEE IS PROCESSED IN TWO WAYS:
TREATMENT OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
WATER RECYCLING:
FIG: FLOW CHART ILLUSTRATING WATER RECYCLING PROCESS
FIG: WATER RECYCLING MECHANISUM
CONVENTIONAL TREATMENT METHODS:
IT HAS 3 TANKS:
FIG: SCHEMATIC FLOW SHEET OF WASTE WATER TREATMENT UNITS
EQUALIZATION TANK:
ANAEROBIC TANK:
AEROBIC TANK:
AIR POLLUTION AND ITS CONTROL IN COFFEE PROCESSING
A. ROASTING
B. QUENCHING
C. COOLING
D. DESTONING
E. GREEN BEAN HANDLING
F. GRINDING
G. DECAFFEINATION
H. CONTROL EQUIPMENT
RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING
COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:
FIG: ANAEROBIC TREATMENT SYSTEM
METHOD OF COFFEE WASTE INTO RESOURCE
1. COFFEE TO COMPOST
2. MUSHROOMING FOOD BUSINESSES
3. WASTE TO ENERGY
4. TEA TIME
5. COFFEE FLOUR
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF CONDENSER
SUPPLIERS OF SPRAY DRYERS
SUPPLIERS OF CENTRIFUGE
SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
SUPPLIERS OF PACKAGING MACHINE
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF GRINDER
SUPPLIERS OF BOILERS
SUPPLIERS OF STAINLESS STEEL TANKS
SUPPLIERS OF WEIGHING SCALE
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF MILK POWDER

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

81 MT/Day
Land & Building

(40,000 sq.mt.)
Plant & Machinery

US$ 13571428
Rate of Return

46%
Break Even Point

30%

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