This document discusses the process of manufacturing instant coffee powder. It begins with an introduction to instant coffee and comparison to freshly brewed coffee. It then covers the history and advent of instant coffee. The main body details the manufacturing process which includes: roasting green coffee beans, grinding them, extracting soluble solids through hot water under pressure, concentrating the extract, drying it through spray drying or freeze drying, and final packaging. Popular brands and the global market overview are also mentioned. Byproducts and references are listed at the end.

1. INSTANT COFFEE POWDER
TECHNOLOGY
BY T.SENTHAMIZH SELVAN

2. INTRODUCTION

3. INSTANT COFFEE
When you brew coffee
as normal, then remove
all of the water from the
finished product, leaving
behind the extracted
solubles in a sort of
crystalline form.

4. Instant Coffee Vs Fresh Ground Coffee.
What is the Difference?
INSTANT COFFEE
 One cup contains 60-80mg of
caffeine.
 Less CGAs
 High phenols and flavonoids
 Low cost
 Convenience
 No by-products
 Less time
FRESHLY BREWED COFFEE
• It contains 60-120mg of caffeine per
cup
• High CGAs
• Low phenols and flavonoids
• Expensive
• Ritual
• By-products
• Time consuming

5. ADVENT OF SINGLE-SERVE INSTANT COFFEES

7. HISTORY OF INSTANT COFFEE

8. .
IN 1771-The first “instant coffee” is made in Britain.
It was called a “coffee compound” and had a patent granted by the
British government.
IN 1851 -First American instant coffee was created.
It was used during the Civil War and experimental “cakes” of instant coffee were
shared in rations to soldiers.
IN 1890-David Strang of Invercargill, New Zealand
invented and patented instant or soluble coffee.

9. IN 1901-First successful method of creating a stable soluble
coffee powder was invented by Japanese-American chemist
Satori Kato of Chicago .

10. • In the times of the World War II, instant coffee is again very
popular among the soldiers.
• In 1954 -Nescafe developed a method to produce instant coffee
using only coffee, without added carbohydrates .

11. In 1937 when Nestle scientist Max Morgenthaler
invents a new instant coffee making method. The new
product is named Nescafe.

12. PRODUCTS

13. TYPES OF INSTANT COFFEE
1.INSTANT COFFEE GRANULES:
This product is just the pure coffee granules, and it usually
comes in a glass jar or a plastic pouch. It will always be 100%
coffee.

14. 2.COFFEE STICKS AND SACHETS:
Pure coffee, but they often contain
sugar and various creamers too.

15. 3.FLAVOURED INSTANT COFFEE

16. POPULAR BRANDS IN THE WORLD

18. POPULAR BRANDS IN INDIA

19. GLOBAL MARKET
-OVERVIEW

28. MANUFACTURING
PROCESS

29. PICTORIAL PROCESS FLOW CHART

30. PROCESS FLOW CHART
RoastingGreen coffee beans Grinding
ExtractionBlending Concentration
Drying & Agglometration
Soluble coffee

31. 1. ROASTING
• Essential step in the production of
high-quality instant coffee.
• This process produces the desired
aroma and taste of the beans.
• Bean heats water begin to evaporate
in an endothermic process.
• Exothermic reaction starts at 160°c
and peak at 210°c

32.  Carbon dioxide water vapour leaves the
bean.
 Gas entraped in cells lead to increase in
bean pressure.
 Bean expands and pop at certain moment.
 When desired degree of color, flavour,
roast ,mass loss beans are discharged from
the roaster.

36. • When the temperature reaches 160 °C, roasting begins, and the
coffee beans start to lose moisture.
• Pyrolytic reactions start at 190 °C, causing many chemical changes
in the coffee beans that are directly related to the degree of
roasting.
• Once the required roasting degree is reached, which must be
within 20 min of the start time.
• The beans must be rapidly cooled, using water or air as a cooling
agent, in order to prevent further volatilization of the aroma,
which would alter the quality of the product

37. 2.GRINDING
• During grinding, the beans are reduced to 0.5–1.1 mm pieces in order to
increase the interface between water and coffee and to facilitate the transfer of
soluble substances into the brew.
• The rupture of coffee bean tissues accelerates the release of carbon dioxide
(CO2) gas and volatile aroma.
• It also absorbs the moisture from air and allows the remaining aroma to be more
easily extracted.

39. 3.EXTRACTION
• The most complex
aspect of instant
coffee processing.
• Temperature and
pressure are the two
important parameters
in the extraction
process.

40. • Coffee ground to a particle size of 1.5 mm are extracted with softened
water in a battery of five to eight percolation columns called cells.
• Hot water is fed into the take containing roasted granules that are almost
extracted and then flows through the various tanks in series before it is
withdrawn from the freshly charged tank
• The process is semi-continuous; water at 160-180°C enters the most
completely extracted cell and circulates through to the most recently
filled cell.
• The cells are divided into
1. COLD CELLS
2. HOT CELLS

41. HOT CELLS
Temperature -140-180°C
Pressure of 14-16 bar.
High molecular-weight
material (in particular
carbohydrates) is extracted.
COLD CELLS
 Material with the most
flavour is extracted.
• Extract is withdrawn from
the fresh cell, cooled to 4-
5°C and sent into a scale in
amounts that depend on
the desired yield (33-55%
based on roasted coffee)
and on the concentration
of the extract (10-30%

42. 4.CONCENTRATION
THREE METHODS:
1. VACUUM EVAPORATION
2. CENTRIFUGATION
3. FREEZE CONCENTRATION
The brewed coffee is treated in one of several ways to increase its
concentration.
The goal is to create an extract that is about 40% solids.

43. VACUUM EVAPORATION
It is the process of causing
the liquid to evaporate at a
lower temperature than
normal, thereby accelerating
the concentration of the
liquid

44. CENTRIFUGATION
It involves the use of a
centrifuge to separate
out the lighter water
from the heavier
coffee.

45. It is a process of cooling the extract enough to freeze the
water and then mechanically separating the ice crystals from
the coffee concentrate

46. 5.DEHYDRATION
Convert the liquid coffee extract to a dry form.
METHODS FOR PRODUCING INSTANT COFFEE:
A.Freeze-drying
B. Spray-drying.

47. A.FREEZE-DRYING METHOD
Preserves the most coffee flavor.
Freeze drying is favoured for it’s
capacity for retaining volatile compounds.
Frozen coffee is placed in the drying
chamber, often on metal trays.
A vacuum is created within the
chamber.
Coffee concentrate is rapidly frozen to
around to -40 to -50°C; ice crystals are
separated and sublimed under vacuum.

48. B.SPRAY-DRYING METHOD
• Transition from liquid coffee to instant coffee takes
only 5 to 30 seconds.
• Coffee or concentrated coffee is sprayed from a high
tower in a large hot-air chamber.

49. As the frozen coffee warms up, the frozen water rapidly expands into gas in a
process called sublimation.
The freeze-dried granules are removed from the chamber and packaged

50. The extract is sprayed through a pressure nozzle into the top of a tower &dried by a
concurrent flow of hot air at 250°C-270°C.
As the droplets fall, the remaining water evaporates. Dry crystals of coffee fall to the
bottom of the chamber.

51.  In this process, due to high
temperatures it affect the oils of the
coffee and more of the flavour is lost.
 It produces too fine of a powder.
 Powder with a bulk density of 230-
300 g/l.
 Moisture content change: IN = 75-
85% OUT = 3-3.5%.
 Air temperature: IN = 270 °C OUT =
110 °C.

52. 6.PACKAGING
• Instant coffee particles are susceptible to the action of
moisture – that is, they absorb moisture from the air.
• If the moisture content increases to 7–8%, the powder or
granules can become a paste or solid mass.
• Instant coffee must therefore be packaged under low
humidity conditions in a moisture-proof container to keep
the product dry until purchased and opened by the
consumer.

53. • Susceptible to oxidation
reactions – that is, a rapid
loss in quality may be caused
by the release of volatiles.
• Generally packaged in glass
jars, vacuum packed in cans,
aluminium foil-lined bags,
flexible polyethylene,
laminated pouches or bags,
or packaged in airtight plastic
beakers or mugs.

54. BYPRODUCTS/WASTE
 Coffee waste can be considered as a
chemical feedstock for the
production of higher value products,
specifically D-mannose and, upon
reduction, D-mannitol, which is a
valuable product in the
pharmaceutical and food industries.
 It contain about 15% cellulose, 25%
mannan and 5% arabino-galactan
(dry basis).

57. REFERENCES
• http://www.coffee-ota.org/
• http://www.fda.gov/Food/default.htm
• https://writepass.com/journal/2012/11/instant-coffee-
production/
• http://www.coffeeinstitute.org/the-q-coffee-system.html
• https://www.coffeeandhealth.org/all-about-coffee/instant-
coffee/
• https://www.thespruceeats.com/instant-coffee-guide-764526
• Coffee Recent Developments Edited by R.J. Clarke and O.G.
Vitzthum.