Production 

1. Green Coffee Pre-Cleaning 

Raw green coffee beans are received and passed through pre-cleaning systems to remove foreign materials such as dust, stones, metals, and broken beans. Equipment typically includes vibrating screens, destoners, magnets, and aspirators. This step ensures consistent quality and protects downstream equipment. 

2. Roasting 

Cleaned green coffee beans are roasted under controlled temperature and time conditions to develop the desired flavors, aroma, and color. Roasting parameters are adjusted based on product specifications. After roasting, beans are rapidly cooled to stop further roasting reactions and preserve aroma compounds.  

3. Extraction  

Roasted coffee beans are ground to a specific particle size and fed into extractors. Hot water is passed through the ground coffee in a controlled manner to dissolve soluble coffee solids. The result is coffee extract, while spent coffee grounds are discharged for disposal or by-product use. 

4. Aroma Recovery System 

Volatile aroma compounds released during roasting and extraction are captured using an aroma recovery system. These aromas are condensed and stored separately under controlled conditions to prevent loss. The recovered aroma is later reintroduced into the product to enhance flavors and sensory quality. 

5. Evaporation 

The dilute coffee extract is concentrated in multi-effect evaporators under vacuum conditions. Water is removed at low temperatures to preserve coffee quality and flavor. The output is a high-solids coffee concentrate suitable for spray drying. 

6. Spray Drying 

The concentrated coffee extract is sprayed into fine droplets and introduced into a spray dryer with hot air. Moisture rapidly evaporates, producing dry instant coffee powder. Dryer parameters are optimized to achieve the desired moisture content, bulk density, and particle size.  

7. Agglomeration 

Spray-dried coffee powder is agglomerated to improve solubility, appearance, and handling properties. Fine particles are re-wetted with steam or coffee extract and gently re-dried to form larger, porous granules. Agglomeration enhances instant dissolution in hot or cold water. 

8. Packing 

Finished instant coffee is packed under hygienic and controlled conditions to protect against moisture, oxygen, and contamination. Packing formats may include jars, pouches, sachets, or bulk packs. Inert gas flushing may be used to extend shelf life and preserve aroma.