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Microsoft Word - Instant Coffee Production 2012 edML School of Engineering Chemical and Environmental Engineering PROC 2078 PROCESS PRINCIPLES INSTANT COFFEE PRODUCTION Aim This project will investigate the feasibility of a multinational company installing an instant coffee production facility in Australia, or an Asian country if it is advantageous to do so. Background A multinational food company is looking at diversifying its manufacturing facilities for the supply of instant coffee in South East Asia and the Pacific. Several locations are under consideration in Australia (including Queensland), Pacific Islands (PNG) and in Asia (East Timor and Malaysia) – all taking advantage of access to local sources of coffee beans. Your firm has been asked to examine the option for investment in Queensland; other firms have been engaged to look at each of the other possible locations to take advantage of their specialised knowledge of local conditions and regulations. The production of instant coffee in Australia has been rationalised to a couple of plants located mainly in New South Wales and Queensland. With the expansion of coffee shops and cafes in Australia, this project was conceived to investigate the possibility of installing another plant in Australia to satisfy this market demand. The plant location would not be limited to Australia if it was shown that an Asian country provided a better return on investment. Process description The process starts from green coffee beans which are roasted, crushed and ground, extracted with hot water and spray dried. The process thus involves a range of unit operations including roasting, size reduction, counter-current extraction and spray drying or freeze-drying. The plant would also include packaging of the product. Scope The scope of the project involves identifying a market need for a particular type of instant coffee, selecting a suitable location within the specified region, specifying the plant capacity, developing the best processing scheme, performing process design with mass and energy balances and process flowsheet, and plant sustainability (economic, environmental and social). Process Principals assignment Background - is a beverage derived from brewed coffee beans that enables people to quickly prepare hot coffee by adding hot water or milk to the powder or crystals and stirring. Instant coffee is commercially prepared by either freeze-drying or spray drying, after which it can be rehydrated. Instant coffee in a concentrated liquid form is also manufactured. Advantages of instant coffee include speed of preparation (instant coffee dissolves quickly in hot water), lower shipping weight and volume than beans or ground coffee (to prepare the same amount of beverage), and long shelf life—though instant coffee can spoil if not kept dry. Instant coffee also reduces cleanup since there are no coffee grounds, and at least one study has found that it has a lower environmental footprint than other preparation methods.[1] Espressois also available in concentrated instant form. The process to make instant espresso is different, espresso coffee is finely ground and brewed as espresso and the already brewed coffee grounds are then taken and dehydrated into crystals https://en.wikipedia.org/wiki/Instant_coffee There are two ways to make instant coffee: spray drying and freeze drying. Spray drying is achieved by spraying liquid coffee concentrate as a fine mist into very hot, dry air (we’re talking about 480 degrees F). When the coffee hits the ground, the water has been evaporated and it has dried into small, round crystals. Freeze drying coffee involves a few steps. First, the coffee is cooked down into an extract. The coffee extract is chilled at about 20 degrees F into a coffee slushie. The coffee slushie is then further chilled on a belt, drum or tray to -40 degrees F until it forms slabs of coffee ice. The coffee ice is broken into granules. They’re then sent to a drying vacuum, where the ice vaporizes and leaves behind instant coffee granules. https://www.huffingtonpost.com.au/entry/what-is-instant-coffee_n_57bda1ebe4b00d9c3a1afc74 Freeze drying coffee info A process for freeze drying coffee extract in the form of pellets combines short freeing times with high drying pressures, saving time and energy in comparison with conventional processes. The thus obtained product has an excellent flavour and its surface reminds one of freshly roasted coffee beans. Freeze-dried coffee extract for use as “instant coffee” is usually produced as granules, whereby aqueous coffee extract with a dry substance content of approximately 40 wt/vol. % is foamed to a foam weight of approximately 450 to 750 g/l, the composition is cooled for approximately 30 minutes on freezing belts to a foam temperature of approximately −45° C. and the frozen product is ground at −40 to −50° C. The thus obtained granules are screened at low temperatures in order to eliminate the fines with grain sizes of less than 0.5 mm and particles with grain sizes above 3 mm. The quantity of fines, i.e. of particles with grain sizes below 0.5 mm, usually accounts for 30 to 35 wt. % of the frozen total product. After screening, approximately 95% of the granules have grain sizes in the range from 0.5 to 3 mm, but often up to 5% of fines with grain sizes of 0.5 mm or less are still present. The proportion of particles between 0.5 mm and 1 mm is approximately 10 to 20% of the screened product. These granules are usually poured into trays and freeze-dried at operating pressures between 0.3 and 0.4 mbar (Capacitron values, corresponding to Thermotron values of approximately 0.4 to 0.6 mbar). The freeze-dried end-product normally has a density of approximately 230 to 260 g/l. As explained above, 30 to 35% of the granules occur as fines which must be eliminated by screening, recycled and reprocessed. The process is cost-intensive, since the energy expended on grinding at low temperatures between approximately −40 and −50° C. and the costs of the screening and grinding stages contribute substantially to the total production costs. Major advantages of the process according to the invention manifest themselves in stage b). There, the pellets dropped onto the cooled belt can be frozen to temperatures between −30 and −40° C. within 2 to 3 minutes. In comparison with conventional processes, an approximately 10-fold saving in time is consequently achieved in this stage. Since the product does not have to be comminuted (ground), and therefore no frictional heat is generated, it is sufficient to freeze the pellets at −30 to −40° C. Energy is therefore also saved in this stage. Spray drying https://patents.google.com/patent/US6428833B1/en Stage One This stage involves the production of large quantities of freshly brewed coffee using industrial bulk brewers. Freshly ground coffee is put into contact with hot water in industrial brewers until the desired degree of extraction has occurred. The process can either be the drip filter method that many use in the home or an industrial version of the coffee percolator. Much waste product is produced in the initial brewing chambers in the form of used coffee grounds. However these days they are recycled for use in animal foods, used as organic fuels or processed as compost Stage Two The resulting coffee liquor liquid is then concentrated through an evaporation process where some of the volatile aroma components are removed and stored to be returned later prior to packing. This stage produces a thick more viscous coffee liquid that is then ready for the next stage in the making of spray dried instant coffee. Stage Three The concentrated liquid coffee is then sent to the spray- drying tower where it is turned into powder. This is achieved by pumping the coffee concentrate through an atomizer where it is broken into small droplets. These droplets react with the hot drying gases in the tower and lose moisture rapidly. They are are suspended in the drying air and typically separated by centrifugal action. The powdered coffee produced can however often be too fine to be easily used. Consequently it often undergoes an additional process called agglomeration, which results in a more useable and appealing product. The fine coffee particles are gathered into larger particles using a partial re-hydration process which produces a more visually tempting finished product somewhere between the consistency of powder and freeze dried coffee. Spray dried coffee is considerably cheaper to produce that freeze dried coffee, the latter of which is considered the higher quality product. Spray Drying is preferred to freeze drying in some cases because of its economy, short drying time, usefulness when dealing with such a heat-sensitive product, and the fine, rounded particles it produces. Spray drying produces spherical particles about 300 micrometres (0.012 in) size with a density of 0.22 g/cm³ (ref 2). To achieve this, nozzle atomization is used. Various ways of nozzle atomization can be used each having its own advantages and disadvantages. High speed rotating wheels operating at speeds of about 20,000 rpm are able to process up to 60,000 pounds (27 tonnes) of solution per hour (ref 3). The use of spray Wheels requires that the drying towers have a wide radius to avoid the atomized droplets collecting onto the drying chamber walls. · Completed in 5–30 seconds (dependent on factors such as heat, size of particle, and diameter of chamber) · Moisture content change: IN = 75-85% OUT = 3-3.5% · Air temperature: IN = 270°C OUT = 110°C http://www.austfood.com/Coffee_Spray_Drying Report Writing Template 1 SCHOOL OF ENGINEERING Title Group Name / Number 3 April, 2020 Your Lecturer Your tutorial and group members Summary One page that sets the problem in context, draws a boundary around what you have done and provides your key outcomes and recommendations. A reader should not have to read more than the Summary to get your message. Suggested areas for inclusion in the summary are shown below: · Problem statement: What problem are you trying to solve? What is the scope of your work (a generalized approach, or for a specific situation)? · Motivation: Why do we care about the problem and the results? · Approach: How did you go about solving or making progress on the problem? · Literature review: What are the main processes used? Compare them briefly and highlight differences. · Results: What are the specific findings and outcomes from your research project? If design based, what did the literature survey, model development show? If experimental based, what are the actual experimental results that you need to show? · Conclusions / Recommendations: What are the implications of your findings and where do you go from here? Are your results general or specific to a particular case? Acknowledgments Table of Contents This TOC is generated automatically from the headers in the subsequent report. You update it by Right Click – Update Field/Update Entire Table. Do not type over it! 71 Introduction 2 Literature Review 8 2.1 Process Choice 1 8 2.2 Process Choice 2 9 2.3 Process Choice 3 9 3 Results 10 3.1 The best process 10 3.2 Process