1. Organisation-Wide Training Philosophy

2. Hands-On Operator Training 

3. Process Operation Training 

4. Supervisor Training 

5. Management Training 

6. Training Delivery Method 

7. Final Outcome 

Organisation-Wide Training Philosophy

Before role-specific training, all employees must share a common understanding of:

• How instant coffee is made

• Why quality, safety, and cost control matter

• How each role affects the final product

Core Objectives

• Build process awareness across departments

• Reduce errors caused by poor handovers or misunderstandings

• Create a continuous improvement culture

Common Foundation Modules (All Employees)

1. Instant Coffee Process Overview

1. • Green coffee sourcing & quality basics

   • Roasting principles

   • Extraction & concentration

   • Drying (spray vs freeze drying)

   • Agglomeration

   • Aroma recovery

   • Packaging & storage

2. Quality & Food Safety

1. • GMP & hygiene

   • HACCP in instant coffee

   • Allergen control (if applicable)

   • Contamination risks (metal, moisture, foreign bodies)

   • Shelf-life and moisture control

3. Safety Culture

1. • High-temperature processes

   • Pressure systems

   • Steam and hot liquids

   • Dust explosion awareness

   • Chemical handling (CIP, cleaning agents)

Hands-On Operator Training

(Operation, Safety & Maintenance)

Target Group

• Machine operators

• Utility operators

• Maintenance technicians (mechanical & electrical)

Training Objectives

• Operate equipment safely, consistently, and efficiently

• Understand cause-and-effect of operating parameters

• Reduce downtime and quality losses

• Build ownership of equipment

Process Operation Training

1. Roasting & Grinding (if in-house)

• Roast profile basics (time, temperature, airflow)

• Impact on extraction yield and flavor

• Grinder settings and particle size control

• Common defects and corrections

2. Extraction

• Extractor types (percolators, batch extractors)

• Key parameters:

  • Temperature

  • Time

  • Coffee-to-water ratio

• Yield vs quality trade-off

• Signs of under- and over-extraction

3. Concentration / Evaporation

• Brix control

• Steam economy

• Fouling and scaling prevention

• Monitoring viscosity and flow

4. Drying Process

Spray Drying

• Atomization principles

• Inlet vs outlet temperature

• Powder moisture control

• Fines generation and recovery

Freeze Drying

• Freezing rate and crystal formation

• Sublimation control

• Vacuum integrity

• Energy efficiency awareness

5. Agglomeration & Aroma Addition

• Particle size distribution

• Rewet properties

• Aroma retention and losses

6. Packaging

• Moisture barrier importance

• Oxygen control

• Sealing integrity

• Coding & traceability

B. Safety Training (Operator-Focused)

• Lockout / Tagout (LOTO)

• Confined space entry (extractors, dryers)

• Working at height (dryers, cyclones)

• Hot surface awareness

• Dust explosion prevention

• Emergency shutdown procedures

C. Maintenance Training

Preventive Maintenance

• Lubrication schedules

• Wear parts identification

• Seal and gasket inspection

• Bearings and vibration basics

Basic Troubleshooting

• Unusual noises

• Temperature deviations

• Flow inconsistencies

• Sensor and instrumentation faults

CIP & Cleaning

• Proper chemical use

• Temperature & time control

• Verification of cleaning effectiveness

Supervisor Training

(Process Control, Troubleshooting & Productivity)

Target Group

• Shift supervisors

• Line leaders

• Production engineers

Training Objectives

• Maintain stable process conditions

• Diagnose and solve problems quickly

• Improve productivity without compromising quality

• Lead people effectively on the floor

A. Advanced Process Control

• Understanding control loops (temperature, pressure, flow)

• Critical Control Points (CCPs)

• Managing process variability

• Statistical Process Control (SPC)

• Trend analysis (before alarms occur)

B. Troubleshooting & Root Cause Analysis

Typical Problems & Diagnosis

• Low extraction yield

• Inconsistent powder moisture

• Dryer fouling

• High fines or dust losses

• Flavor deviations

• High energy consumption

Tools

• Root Cause Analysis (5 Whys, Fishbone)

• Pareto analysis

• Failure Mode & Effects Analysis (FMEA)

C. Productivity & Efficiency

• OEE (Overall Equipment Effectiveness)

• Downtime analysis

• Changeover reduction

• Yield improvement strategies

• Waste reduction (water, coffee solids, aroma losses)

D. People & Shift Management

• Shift handover best practices

• Coaching operators

• Safety leadership

• Conflict resolution

• Performance feedback

Management Training

(Performance, Cost Control & Process Optimisation)

Target Group

• Plant managers

• Operations managers

• Quality managers

• Engineering managers

Training Objectives

• Make data-driven decisions

• Balance quality, cost, and output

• Drive continuous improvement

• Align operations with business strategy

A. Performance Management

• Key KPIs in instant coffee:

  • Yield

  • Energy per kg

  • Water consumption

  • Downtime

  • Quality complaints

• KPI dashboards and reviews

• Cross-department alignment

B. Cost Control

• Cost breakdown of instant coffee:

  • Green coffee

  • Energy (steam, electricity)

  • Water

  • Packaging

  • Labor

• Yield loss impact on profitability

• Energy optimization opportunities

• Maintenance cost vs downtime trade-offs

C. Process Optimisation

• Debottlenecking

• Capacity expansion strategies

• Technology upgrades (dryers, evaporators)

• Automation and digitalisation

• Sustainability initiatives (water & energy reuse)

D. Leadership & Culture

• Building a safety-first culture

• Encouraging problem-solving at all levels

• Continuous improvement mindset (Kaizen)

• Training ROI measurement

Training Delivery Method

Recommended Approach

• Classroom + shop-floor training

• SOP-based learning

• Simulations & case studies

• Mentoring and shadowing

• Periodic assessments and certification

Evaluation

• Written knowledge checks

• Practical skill demonstrations

• KPI improvement tracking

• Safety incident reduction

Final Outcome

After full implementation, the organisation should achieve:

• Safer operations

• Consistent product quality

• Higher yields and lower costs

• Faster problem resolution

• Stronger ownership and accountability at all levels