Process Technologies for Coffee Industry

COFFEEProcess Technologies for the Convenient Coffee IndustryCOFFEEProcessTechnologiesfor theConvenientCoffeeIndustryNiro Niro A/S • Gladsaxevej 305 • PO Box 45 • DK-2860 Soeborg • DenmarkTel: +45 39 54 54 54 • Fax: +45 39 54 58 00 • food.dairy@niro.dk • www.niro.comNiro A/SNiro is a world leader in industrialdrying, with spray drying, freeze drying, and fluid bed processing ascore technologies. The Niro companiesare part of the Process EngineeringDivision of the GEA Group.Process EngineeringDivisionA company of mg technologies groupBNA 828/GB 09/02 opusN I R O P O W D E R T E C H N O L O G YN I R O P O W D E R T E C H N O L O G YB L A C K A S T H E D E V I L , H O T A S H E L L , P U R E A S A N A N G E L , S W E E T A S L O V EArabic ProverbLEAVE THIS FLAP OPEN WHILE READING Process EngineeringDivision3681 ny 09/09/02 16:44 Side 1COFFEEProcess Technologies for the Convenient Coffee IndustryCOFFEEProcessTechnologiesfor theConvenientCoffeeIndustryNiro Niro A/S • Gladsaxevej 305 • PO Box 45 • DK-2860 Soeborg • DenmarkTel: +45 39 54 54 54 • Fax: +45 39 54 58 00 • food.dairy@niro.dk • www.niro.comNiro A/SNiro is a world leader in industrialdrying, with spray drying, freeze drying, and fluid bed processing ascore technologies. The Niro companiesare part of the Process EngineeringDivision of the GEA Group.Process EngineeringDivisionA company of mg technologies groupBNA 828/GB 09/02 opusN I R O P O W D E R T E C H N O L O G YN I R O P O W D E R T E C H N O L O G YB L A C K A S T H E D E V I L , H O T A S H E L L , P U R E A S A N A N G E L , S W E E T A S L O V EArabic ProverbLEAVE THIS FLAP OPEN WHILE READING Process EngineeringDivision3681 ny 09/09/02 16:44 Side 1page 2for EveryPerfectionTasteModern technology hasmade the full-bodied,aromatic, perfect cup ofcoffee convenient. And Niro makes it possible – every day, all over the world.T H E R E A R E T H R E EM A I N S O R T S O F C O F F E E : A R A B I C A ,R O B U S T A , A N DL I B E R I C A . T H E M O S TP O P U L A R I S A R A B I C A ,W H I C H C O M P R I S E S7 5 % O F T H E G L O B A LC O F F E E P R O D U C T I O N .ConvenientConvenient Coffee Factspage 3Setting the StandardsCoffee is pleasure. Its taste, flavour,aroma, and refreshing effect make itunique. It is also a product that attractsgreat attention in the food and beverage industry. And in the technology used to manufacture canned liquid coffee as well as regularand agglomerated instant coffee, Nirosets the standards for others to follow.Helping You to the Best SolutionA successful delivery is more than supplying the best plant available.Consumer requirements vary frommarket to market, and the coffee thatcommands a premium price in onemarket may fail completely in another.From a wide range of processing possibilities, we select the best planttype, layout, and operation to meet thecustomer's specifications of the desiredproduct properties.The Proven AbilityWe have maintained our leading position by repeatedly proving ourability to provide reliable and innova-tive technical solutions for the entireprocess from product testing to plantinstallation and after sales support.Our constant dedication to providingcutting-edge quality to our customersis the main reason why we have installed more than 180 plants for thecoffee industry worldwide.A Complete RangeWe supply solutions for all aspects ofsuccessful coffee production, makingus the obvious supplier of individualplants as well as complete lines. Oursolutions include our own uniquetechnologies as well as equipmentfrom trusted partners in coffee beanhandling, roasting, and packing of thefinished product. No matter the plant or process line,our customer will experience not onlyan increase in product quality, but alsosignificant cost reductions due to efficient waste treatment and recyclesystems.Our commitment extends beyond theactual plants. A strong internationalnetwork of companies gives our customers the comfort of local servicecombined with the quality that comesfrom global presence.RWAConvenient CoffeeProcessOverviewAgglomerationFor dustless powderand customized granulesGreen Bean TreatmentSolutions for cleaning,blending, and storageRoastingBatch mode or continuous operationRoast Bean TreatmentSolutions for storage,grinding, and conditioning of the roasted productExtractionBatch mode or continuous operationExtract TreatmentClarification, storage and aromarecovery from the coffee extractConcentrationFreeze and thermal concentration,membrane filtrationDryingThe full rangeof solutions –only from NiroCIP SystemFast and flexible Cleaning-In-Place featuresProcess ControlPlant supervision and monitoring, recipe control,and logging functionalityPackingPowder: Packed in bulkor retail quantitiesLiquid: Supplied incans or drumsNOZZLE Fluidized Spray FILTERMAT® Freeze DryersTOWER™-NT Dryer -FSD™ Spray Dryer -FMD3681 ny 09/09/02 16:48 Side 4page 2for EveryPerfectionTasteModern technology hasmade the full-bodied,aromatic, perfect cup ofcoffee convenient. And Niro makes it possible – every day, all over the world.T H E R E A R E T H R E EM A I N S O R T S O F C O F F E E : A R A B I C A ,R O B U S T A , A N DL I B E R I C A . T H E M O S TP O P U L A R I S A R A B I C A ,W H I C H C O M P R I S E S7 5 % O F T H E G L O B A LC O F F E E P R O D U C T I O N .ConvenientConvenient Coffee Factspage 3Setting the StandardsCoffee is pleasure. Its taste, flavour,aroma, and refreshing effect make itunique. It is also a product that attractsgreat attention in the food and beverage industry. And in the technology used to manufacture canned liquid coffee as well as regularand agglomerated instant coffee, Nirosets the standards for others to follow.Helping You to the Best SolutionA successful delivery is more than supplying the best plant available.Consumer requirements vary frommarket to market, and the coffee thatcommands a premium price in onemarket may fail completely in another.From a wide range of processing possibilities, we select the best planttype, layout, and operation to meet thecustomer's specifications of the desiredproduct properties.The Proven AbilityWe have maintained our leading position by repeatedly proving ourability to provide reliable and innova-tive technical solutions for the entireprocess from product testing to plantinstallation and after sales support.Our constant dedication to providingcutting-edge quality to our customersis the main reason why we have installed more than 180 plants for thecoffee industry worldwide.A Complete RangeWe supply solutions for all aspects ofsuccessful coffee production, makingus the obvious supplier of individualplants as well as complete lines. Oursolutions include our own uniquetechnologies as well as equipmentfrom trusted partners in coffee beanhandling, roasting, and packing of thefinished product. No matter the plant or process line,our customer will experience not onlyan increase in product quality, but alsosignificant cost reductions due to efficient waste treatment and recyclesystems.Our commitment extends beyond theactual plants. A strong internationalnetwork of companies gives our customers the comfort of local servicecombined with the quality that comesfrom global presence.RWAConvenient CoffeeProcessOverviewAgglomerationFor dustless powderand customized granulesGreen Bean TreatmentSolutions for cleaning,blending, and storageRoastingBatch mode or continuous operationRoast Bean TreatmentSolutions for storage,grinding, and conditioning of the roasted productExtractionBatch mode or continuous operationExtract TreatmentClarification, storage and aromarecovery from the coffee extractConcentrationFreeze and thermal concentration,membrane filtrationDryingThe full rangeof solutions –only from NiroCIP SystemFast and flexible Cleaning-In-Place featuresProcess ControlPlant supervision and monitoring, recipe control,and logging functionalityPackingPowder: Packed in bulkor retail quantitiesLiquid: Supplied incans or drumsNOZZLE Fluidized Spray FILTERMAT® Freeze DryersTOWER™-NT Dryer -FSD™ Spray Dryer -FMD3681 ny 09/09/02 16:48 Side 4page 2for EveryPerfectionTasteModern technology hasmade the full-bodied,aromatic, perfect cup ofcoffee convenient. And Niro makes it possible – every day, all over the world.T H E R E A R E T H R E EM A I N S O R T S O F C O F F E E : A R A B I C A ,R O B U S T A , A N DL I B E R I C A . T H E M O S TP O P U L A R I S A R A B I C A ,W H I C H C O M P R I S E S7 5 % O F T H E G L O B A LC O F F E E P R O D U C T I O N .ConvenientConvenient Coffee Factspage 3Setting the StandardsCoffee is pleasure. Its taste, flavour,aroma, and refreshing effect make itunique. It is also a product that attractsgreat attention in the food and beverage industry. And in the technology used to manufacture canned liquid coffee as well as regularand agglomerated instant coffee, Nirosets the standards for others to follow.Helping You to the Best SolutionA successful delivery is more than supplying the best plant available.Consumer requirements vary frommarket to market, and the coffee thatcommands a premium price in onemarket may fail completely in another.From a wide range of processing possibilities, we select the best planttype, layout, and operation to meet thecustomer's specifications of the desiredproduct properties.The Proven AbilityWe have maintained our leading position by repeatedly proving ourability to provide reliable and innova-tive technical solutions for the entireprocess from product testing to plantinstallation and after sales support.Our constant dedication to providingcutting-edge quality to our customersis the main reason why we have installed more than 180 plants for thecoffee industry worldwide.A Complete RangeWe supply solutions for all aspects ofsuccessful coffee production, makingus the obvious supplier of individualplants as well as complete lines. Oursolutions include our own uniquetechnologies as well as equipmentfrom trusted partners in coffee beanhandling, roasting, and packing of thefinished product. No matter the plant or process line,our customer will experience not onlyan increase in product quality, but alsosignificant cost reductions due to efficient waste treatment and recyclesystems.Our commitment extends beyond theactual plants. A strong internationalnetwork of companies gives our customers the comfort of local servicecombined with the quality that comesfrom global presence.RWAConvenient CoffeeProcessOverviewAgglomerationFor dustless powderand customized granulesGreen Bean TreatmentSolutions for cleaning,blending, and storageRoastingBatch mode or continuous operationRoast Bean TreatmentSolutions for storage,grinding, and conditioning of the roasted productExtractionBatch mode or continuous operationExtract TreatmentClarification, storage and aromarecovery from the coffee extractConcentrationFreeze and thermal concentration,membrane filtrationDryingThe full rangeof solutions –only from NiroCIP SystemFast and flexible Cleaning-In-Place featuresProcess ControlPlant supervision and monitoring, recipe control,and logging functionalityPackingPowder: Packed in bulkor retail quantitiesLiquid: Supplied incans or drumsNOZZLE Fluidized Spray FILTERMAT® Freeze DryersTOWER™-NT Dryer -FSD™ Spray Dryer -FMD3681 ny 09/09/02 16:48 Side 4Great Coffee Comes from Great PlantsCoffee beans are seeds from coffee fruits. After removal of the pulp, thegreen coffee beans are dried, cleanedand packed – typically in 60 kg bags –and stored until they can be roastedand, if required, decaffeinated. Roasting is a delicate process, part artand part science, where the roast master must decide exactly how longand hard the beans are to be roasted to get the desired result. It is during roasting that the beans acquire the flavour and colour of the finished coffee. The beans are now ready forsale to consumers.Or they can be ground and processedinto convenient coffee. And no matterthe process, Niro knows how.At a GlanceQuality SolutionsC O F F E E B E A N S A R ES E E D S F R O M T H E F R U I TO F T H E C O F F E E B U S H .W H E N R O A S T E D , T H EB E A N S L O S E 1 5 - 2 0 % O FT H E I R W E I G H T , B U TI N C R E A S E U P T O 2 5 %I N S I Z E .page 4Convenient Coffee FactsC O F F E E F R U I TPulpGreen beanSilverskinGreen Bean Treatment• Cleaning• Blending• StorageRoastingRoast Bean Treatment• Storage• Grinding• ConditioningExtraction• Fast instant coffee extractors (FIC™)• Conventional batch percolators• Continuous counter-current extractors (CONTEX™)Extract Treatment• Aroma recovery• ClarificationConcentration• Falling film and plate evaporators• Freeze concentrators• Membrane filtration systemsDrying• NOZZLE TOWER™ spray dryers (NT)• Fluidized bed spray dryers (FSD™)• FILTERMAT® spray dryers (FMD)• Continuous freeze dryers (CONRAD™)• Batch freeze dryers (RAY™)Agglomeration• Rewet agglomerators (RWA)PackingProcess lines for convenient coffee production comprise a combination of the process systems listed on thispage. Every part is designed to achieve the quantity and quality ofconvenient coffee specified by the customer.In order to demonstrate and developthe capability of our instant coffee process systems, we have installed thefull range in pilot scale in our test station in Denmark. Test work can be conducted upon request.3681 ny 09/09/02 16:54 Side 7Great Coffee Comes from Great PlantsCoffee beans are seeds from coffee fruits. After removal of the pulp, thegreen coffee beans are dried, cleanedand packed – typically in 60 kg bags –and stored until they can be roastedand, if required, decaffeinated. Roasting is a delicate process, part artand part science, where the roast master must decide exactly how longand hard the beans are to be roasted to get the desired result. It is during roasting that the beans acquire the flavour and colour of the finished coffee. The beans are now ready forsale to consumers.Or they can be ground and processedinto convenient coffee. And no matterthe process, Niro knows how.At a GlanceQuality SolutionsC O F F E E B E A N S A R ES E E D S F R O M T H E F R U I TO F T H E C O F F E E B U S H .W H E N R O A S T E D , T H EB E A N S L O S E 1 5 - 2 0 % O FT H E I R W E I G H T , B U TI N C R E A S E U P T O 2 5 %I N S I Z E .page 4Convenient Coffee FactsC O F F E E F R U I TPulpGreen beanSilverskinGreen Bean Treatment• Cleaning• Blending• StorageRoastingRoast Bean Treatment• Storage• Grinding• ConditioningExtraction• Fast instant coffee extractors (FIC™)• Conventional batch percolators• Continuous counter-current extractors (CONTEX™)Extract Treatment• Aroma recovery• ClarificationConcentration• Falling film and plate evaporators• Freeze concentrators• Membrane filtration systemsDrying• NOZZLE TOWER™ spray dryers (NT)• Fluidized bed spray dryers (FSD™)• FILTERMAT® spray dryers (FMD)• Continuous freeze dryers (CONRAD™)• Batch freeze dryers (RAY™)Agglomeration• Rewet agglomerators (RWA)PackingProcess lines for convenient coffee production comprise a combination of the process systems listed on thispage. Every part is designed to achieve the quantity and quality ofconvenient coffee specified by the customer.In order to demonstrate and developthe capability of our instant coffee process systems, we have installed thefull range in pilot scale in our test station in Denmark. Test work can be conducted upon request.3681 ny 09/09/02 16:54 Side 7page 6ExtractionNiro’s new and unique Fast InstantCoffee (FIC™) extractor is a continuoussystem that features automated multi-extraction percolators. Fully integrated with a PC/PLC(Programmable Logic Controller) system, the FIC™ yields a uniform extract quality.Short Extraction Time – Superior Aroma ProfileThe FIC™ extractor reduces the extraction time by 50%. Water is directed through the ground coffee intwo stages. The process results in twocompletely separate extract fractions,aroma and hydrolysis. The FIC™ extractor gives a superioraroma profile, which is ideal for highquality convenient coffee production.After the process is completed, theextract is filtered and centrifuged.The layout of the percolator columnsgives a compact design and reducesspace requirements compared to standard battery extraction units.The Best ResultsBegin with theBest Extractionpage 7FIC™Extractor – bottom viewFIC™Extractor– top viewConventionalbatch percolator– bottom viewConventionalbatch percolator– top viewN I R O P O W D E R T E C H N O L O G YA T Y P I C A L A R A B I C A C O F F E EB U S H B E A R S A B O U T 5 K GO F F R U I T P E R Y E A R . T H I S C O R R E S P O N D S T O A B O U T 3 0 0 - 4 0 0 G R A M S O FI N S T A N T C O F F E E . F O R R O B U S T A B U S H E S , T H E Y I E L D I S S L I G H T L Y H I G H E R .Convenient Coffee FactsThe conventional batch extractor has awell-known design with the percolatorcolumns in a straight line. With its proven efficiency, it is used in instantcoffee plants around the world.High YieldNiro’s extractors are designed to process a variety of coffee types as efficiently as possible. This gives the customer unparalleled flexibilityand the highest obtainable yield.3681 ny 09/09/02 16:55 Side 9page 6ExtractionNiro’s new and unique Fast InstantCoffee (FIC™) extractor is a continuoussystem that features automated multi-extraction percolators. Fully integrated with a PC/PLC(Programmable Logic Controller) system, the FIC™ yields a uniform extract quality.Short Extraction Time – Superior Aroma ProfileThe FIC™ extractor reduces the extraction time by 50%. Water is directed through the ground coffee intwo stages. The process results in twocompletely separate extract fractions,aroma and hydrolysis. The FIC™ extractor gives a superioraroma profile, which is ideal for highquality convenient coffee production.After the process is completed, theextract is filtered and centrifuged.The layout of the percolator columnsgives a compact design and reducesspace requirements compared to standard battery extraction units.The Best ResultsBegin with theBest Extractionpage 7FIC™Extractor – bottom viewFIC™Extractor– top viewConventionalbatch percolator– bottom viewConventionalbatch percolator– top viewN I R O P O W D E R T E C H N O L O G YA T Y P I C A L A R A B I C A C O F F E EB U S H B E A R S A B O U T 5 K GO F F R U I T P E R Y E A R . T H I S C O R R E S P O N D S T O A B O U T 3 0 0 - 4 0 0 G R A M S O FI N S T A N T C O F F E E . F O R R O B U S T A B U S H E S , T H E Y I E L D I S S L I G H T L Y H I G H E R .Convenient Coffee FactsThe conventional batch extractor has awell-known design with the percolatorcolumns in a straight line. With its proven efficiency, it is used in instantcoffee plants around the world.High YieldNiro’s extractors are designed to process a variety of coffee types as efficiently as possible. This gives the customer unparalleled flexibilityand the highest obtainable yield.3681 ny 09/09/02 16:55 Side 9page 9page 8Aroma RecoveryTo prevent the desired, and volatile,aroma components in the extract frombeing lost during thermal concentration,the extract fractions are stripped of theirvolatiles in an aroma recovery unit.After being stripped from the concentrate in a flash evaporator, thearoma is recovered in a two-stage condenser system.ClarificationIn order to achieve international standards for convenient coffee, clarification is an essential part of theprocess. A system consisting of filtersand centrifuges is used to separate insoluble parts from the extract.ConcentrationConcentration serves the dual purposeof increasing the solids content in theextract prior to freeze or spray drying,and making the process as economical as possible.The aroma being quite volatile, lenientprocessing conditions throughout the1. Evaporator – bottom view2. MembranefiltrationExtract Treatmentconcentration process are essential. Nirohas developed a number of processesthat maximize efficiency while being aslenient to the extract as possible.Thermal ConcentrationOur multistage non-recirculating evaporators operate under vacuum in a plug flow mode. They concentrate the coffee extract gently, quickly, and efficiently. In combination with thearoma recovery system, the evaporatorpreserves the aroma and taste components and produces an excellentconcentrate for the production of convenient coffee.Membrane FiltrationThe aroma fraction of the extract can bepre-concentrated using reverse osmosisin a membrane filtration system. Thisslightly changes the taste profile, whichis an advantage for some coffees and insome markets.Freeze ConcentrationWith Niro’s freeze concentration process, aroma loss due to thermaldegradation is eliminated. By coolingthe extract to subzero temperatures,excess water is removed as ice crystals. And this process requires nowastewater treatment, as the melted ice crystals are pure water.Gentle Liquid Processing:Aroma recoveryFreeze concentratorN I R O P O W D E R T E C H N O L O G YI N 2 0 0 1 / 0 2 , T H E G L O B A L C O F F E E P R O D U C T I O N T O T A L L E DO V E R 6 . 6 M I L L I O NT O N S O F G R E E NB E A N S . T H I S C O R R E S P O N D S T O J U S TU N D E R 9 4 2 B I L L I O N C U P S O F C O F F E E .Convenient Coffee Facts3681 ny 09/09/02 16:56 Side 11page 9page 8Aroma RecoveryTo prevent the desired, and volatile,aroma components in the extract frombeing lost during thermal concentration,the extract fractions are stripped of theirvolatiles in an aroma recovery unit.After being stripped from the concentrate in a flash evaporator, thearoma is recovered in a two-stage condenser system.ClarificationIn order to achieve international standards for convenient coffee, clarification is an essential part of theprocess. A system consisting of filtersand centrifuges is used to separate insoluble parts from the extract.ConcentrationConcentration serves the dual purposeof increasing the solids content in theextract prior to freeze or spray drying,and making the process as economical as possible.The aroma being quite volatile, lenientprocessing conditions throughout the1. Evaporator – bottom view2. MembranefiltrationExtract Treatmentconcentration process are essential. Nirohas developed a number of processesthat maximize efficiency while being aslenient to the extract as possible.Thermal ConcentrationOur multistage non-recirculating evaporators operate under vacuum in a plug flow mode. They concentrate the coffee extract gently, quickly, and efficiently. In combination with thearoma recovery system, the evaporatorpreserves the aroma and taste components and produces an excellentconcentrate for the production of convenient coffee.Membrane FiltrationThe aroma fraction of the extract can bepre-concentrated using reverse osmosisin a membrane filtration system. Thisslightly changes the taste profile, whichis an advantage for some coffees and insome markets.Freeze ConcentrationWith Niro’s freeze concentration process, aroma loss due to thermaldegradation is eliminated. By coolingthe extract to subzero temperatures,excess water is removed as ice crystals. And this process requires nowastewater treatment, as the melted ice crystals are pure water.Gentle Liquid Processing:Aroma recoveryFreeze concentratorN I R O P O W D E R T E C H N O L O G YI N 2 0 0 1 / 0 2 , T H E G L O B A L C O F F E E P R O D U C T I O N T O T A L L E DO V E R 6 . 6 M I L L I O NT O N S O F G R E E NB E A N S . T H I S C O R R E S P O N D S T O J U S TU N D E R 9 4 2 B I L L I O N C U P S O F C O F F E E .Convenient Coffee Facts3681 ny 09/09/02 16:56 Side 11page 11page 10Freeze drying preserves all the desirable aspects of the concentratedcoffee extract. The finished productcommands a premium price acrossthe world by meeting marketdemands for quality parameters suchas colour, density, and solubility.The Atlas freeze drying process fromNiro enables a unique degree of con-trol over all of these crucial qualityparameters. Freeze DryingThe frozen coffeeis prebrokenFreeze drying: Tray going intothe CONRAD™freeze dryerFreeze drying: Tray with the finished productFreeze dryingBy using the proven StructureControl System (SCS), productcolour and solubility as well as bulkdensity can be controlled during thepre-freezing process to meet anyrequirements. Actual freezing can take place on a Continuous Air Blast (CAB) beltfreezer or for smaller capacities on a Rota Drum freezer.Granulation of the frozen coffeeslabs in a carefully designed systemensures the right granule size andsize distribution and completes theprocess prior to freeze drying.The unique CONRAD™ freezedryer protects all the qualities obtained in the concentrate duringthe full-automatic, continuousoperation, and a first-class solublecoffee is produced thanks to theintegrated control system for theentire process.Our RAY™ batch freeze dryers are used for smaller capacityrequirements or as add-on units toexisting coffee processing plants.The Premium Product:1234 5152N I R O P O W D E R T E C H N O L O G Y43Foaming andprefreezing CAB freezingRAY™ batch freeze dryerC O F F E E I S G R O W N I N A W I D E B E L T A R O U N DT H E E Q U A T O R .R O B U S T A C O F F E E C A NG R O W F R O M S E A L E V E LT O 7 0 0 M E T R E S A L T I T U D E , W H E R E A SA R A B I C A C O F F E E M U S TB E G R O W N A T A N A L T I T U D E B E T W E E N1 , 0 0 0 A N D 2 , 0 0 0M E T R E S .Convenient Coffee FactsCONRAD™ freeze dryer663681 ny 09/09/02 16:57 Side 13page 11page 10Freeze drying preserves all the desirable aspects of the concentratedcoffee extract. The finished productcommands a premium price acrossthe world by meeting marketdemands for quality parameters suchas colour, density, and solubility.The Atlas freeze drying process fromNiro enables a unique degree of con-trol over all of these crucial qualityparameters. Freeze DryingThe frozen coffeeis prebrokenFreeze drying: Tray going intothe CONRAD™freeze dryerFreeze drying: Tray with the finished productFreeze dryingBy using the proven StructureControl System (SCS), productcolour and solubility as well as bulkdensity can be controlled during thepre-freezing process to meet anyrequirements. Actual freezing can take place on a Continuous Air Blast (CAB) beltfreezer or for smaller capacities on a Rota Drum freezer.Granulation of the frozen coffeeslabs in a carefully designed systemensures the right granule size andsize distribution and completes theprocess prior to freeze drying.The unique CONRAD™ freezedryer protects all the qualities obtained in the concentrate duringthe full-automatic, continuousoperation, and a first-class solublecoffee is produced thanks to theintegrated control system for theentire process.Our RAY™ batch freeze dryers are used for smaller capacityrequirements or as add-on units toexisting coffee processing plants.The Premium Product:1234 5152N I R O P O W D E R T E C H N O L O G Y43Foaming andprefreezing CAB freezingRAY™ batch freeze dryerC O F F E E I S G R O W N I N A W I D E B E L T A R O U N DT H E E Q U A T O R .R O B U S T A C O F F E E C A NG R O W F R O M S E A L E V E LT O 7 0 0 M E T R E S A L T I T U D E , W H E R E A SA R A B I C A C O F F E E M U S TB E G R O W N A T A N A L T I T U D E B E T W E E N1 , 0 0 0 A N D 2 , 0 0 0M E T R E S .Convenient Coffee FactsCONRAD™ freeze dryer663681 ny 09/09/02 16:57 Side 13Rewet agglomeratorpage 13page 12RWASpray DryingThe most economic method for producing soluble coffee is spray drying, which results in free-flowingand agglomerated/granulated powders. Thanks to an extremelyhigh level of control, our customerscan manufacture products meetingthe demands of their individual markets.The design of the spray dryerdepends upon the specified powderproperties, e.g. moisture content, particle size, and bulk density. Niro offers three designs for the manufacture of soluble coffee:NOZZLE TOWER™ (NT) spray dryers are used for producing free-flowing powders comprising individual round, soluble beads withaverage particle sizes ranging from100 to 250 microns. The tower-likechamber design results in a long residence time for the product to be dried. Fluidized Spray Dryers (FSD™), equipped with an integrated fluidbed, are extremely compact. In orderto achieve the required moisture 1 2 35123 4Spray dryer – top viewSpray dryer – side viewSpray dryer – bottom viewAgglomerationDifferent markets require different types of convenient soluble coffee.To meet the demand for granulated, dust-free products, the powder isprocessed in a Rewet Agglomerator (RWA). Material handling duringthe agglomeration process itself is specially controlled according tothe desired properties of the end product.Average particle size is above 1000 microns.Spray Drying Spray Dryer-FSD™NOZZLE TOWER™-NT FILTERMAT®-FMDThe Proven Quality:N I R O P O W D E R T E C H N O L O G YSpray drying: The FSD™ processVIBRO-FLUIDIZER®content and temperature of the instant coffee, post-drying and cooling are carried out in an external VIBRO-FLUIDIZER®. The FSD™s produce a free-flowing agglomerated/granulated coffeepowder with average particle sizesbetween 100 and 300 microns. Thelower temperatures during dryinggive improved aroma properties.The FILTERMAT® Spray Dryer (FMD)with an integrated conveyor beltoffers an even lower temperature profile and longer drying timesduring the entire process. The resultis a coarse, agglomerated/granular,free-flowing, and dustless powderwith average particle sizes of 250 to1000 microns with a greatly increasedaroma retention.With a proven ability of controllingpowder properties to a uniquedegree, the operators of Niro spraydryers can adjust production to market trends and requirements.Fluidized spray dryer (FSD™)with integrated fluid bed.A P P R O X . 2 0 % O F A L LP R O C E S S E D C O F F E EB E A N S A R E U S E D F O RM A K I N G I N S T A N T C O F F E E , A F I G U R ET H A T H A S B E E N S T A B L EF O R T H E L A S T D E C A D E .Convenient Coffee Facts453681 ny 09/09/02 16:58 Side 15Rewet agglomeratorpage 13page 12RWASpray DryingThe most economic method for producing soluble coffee is spray drying, which results in free-flowingand agglomerated/granulated powders. Thanks to an extremelyhigh level of control, our customerscan manufacture products meetingthe demands of their individual markets.The design of the spray dryerdepends upon the specified powderproperties, e.g. moisture content, particle size, and bulk density. Niro offers three designs for the manufacture of soluble coffee:NOZZLE TOWER™ (NT) spray dryers are used for producing free-flowing powders comprising individual round, soluble beads withaverage particle sizes ranging from100 to 250 microns. The tower-likechamber design results in a long residence time for the product to be dried. Fluidized Spray Dryers (FSD™), equipped with an integrated fluidbed, are extremely compact. In orderto achieve the required moisture 1 2 35123 4Spray dryer – top viewSpray dryer – side viewSpray dryer – bottom viewAgglomerationDifferent markets require different types of convenient soluble coffee.To meet the demand for granulated, dust-free products, the powder isprocessed in a Rewet Agglomerator (RWA). Material handling duringthe agglomeration process itself is specially controlled according tothe desired properties of the end product.Average particle size is above 1000 microns.Spray Drying Spray Dryer-FSD™NOZZLE TOWER™-NT FILTERMAT®-FMDThe Proven Quality:N I R O P O W D E R T E C H N O L O G YSpray drying: The FSD™ processVIBRO-FLUIDIZER®content and temperature of the instant coffee, post-drying and cooling are carried out in an external VIBRO-FLUIDIZER®. The FSD™s produce a free-flowing agglomerated/granulated coffeepowder with average particle sizesbetween 100 and 300 microns. Thelower temperatures during dryinggive improved aroma properties.The FILTERMAT® Spray Dryer (FMD)with an integrated conveyor beltoffers an even lower temperature profile and longer drying timesduring the entire process. The resultis a coarse, agglomerated/granular,free-flowing, and dustless powderwith average particle sizes of 250 to1000 microns with a greatly increasedaroma retention.With a proven ability of controllingpowder properties to a uniquedegree, the operators of Niro spraydryers can adjust production to market trends and requirements.Fluidized spray dryer (FSD™)with integrated fluid bed.A P P R O X . 2 0 % O F A L LP R O C E S S E D C O F F E EB E A N S A R E U S E D F O RM A K I N G I N S T A N T C O F F E E , A F I G U R ET H A T H A S B E E N S T A B L EF O R T H E L A S T D E C A D E .Convenient Coffee Facts453681 ny 09/09/02 16:58 Side 15Process control roompage 15page 14Process ControlControlling and monitoring a process line is of the essence for any operator. Niro’s proven process control system meets all requirements for safety, flexibility,and ease of use.Using standard hardware components, the process system enables you to:Supervise and monitor automaticplant start up, shut down, and cleaning proceduresWork with several product recipes in one systemLog every process activity for real-time and historical trendingInstrument and system specifications are selected in cooperation with our customer toensure the best hardware serviceduring the lifetime of the plant. CIP SystemCleaning, while necessary, can be anexpensive and time-consuming partof the process. Drawing on over 70years of experience in working withsanitary processes, Niro has developed a series of Cleaning-In-Place (CIP) systems.With features such as retractablenozzles in the main drying chamberas well as highly efficient processwater recovery, the CIP systemmakes a significant contribution to the profitability of the entire process line.A Partnership of SharingDuring engineering, commissio-ning/start-up and after-sales servicewe support our customers in theirefforts to increase process profit-ability. A partnership, where bothsides – Niro and the customer –learn about each other and shareexpertise and new experiences.A Partnership of SuccessNiro is a resource in every stage ofthe project. We have the experienceand know-how to ensure that allaspects are completed as smoothlyas possible, including: •••Available Sizes IC-125 IC-250 IC-500Green coffee input (kg/h) 275-375 550-750 1100-150010% H2ORoasted, ground coffee (hg/h) 240-330 480-650 960-13006% H2OYield % 39-52 39-52 39-52Instant coffee (kg/h) 125 250 5003% H2OAnnual production (t/year) 940 1875 3750Based on: 7,500 (h/year)with the Requirement Meeting Everythan Just Morea Plant…N I R O P O W D E R T E C H N O L O G YPlant sizesGeneral operational data for InstantCoffee (IC) plants are given in thetable. Available Sizes refer to theamount of kg that is produced each hour, i.e. an IC-250 plant will produce 250 kg of instant coffeeeach hour.Best in CIP and Process Control• Project financing• Product testing at our test station in Denmark• Process evaluation and optimisation• Design and engineering• Project management• Plant delivery, installation and commissioning• Training of plant operators• Technical service and supply of spare partsA unique range of technologies and the service to match – these are thereasons why choosing Niro means entering a partnership of success.C O N S U M P T I O N V A R I E S : I NN O R T H A M E R I C A , T H ER A T I O I S 4 . 4 % I N S T A N TC O F F E E T O 9 5 . 6 % F R E S H .I N E A S T E R N E U R O P E , I TI S 6 5 % I N S T A N T T O 3 5 %F R E S H , A N D I NA U S T R A L A S I A , T H E R A T I OI S 7 8 % T O 2 2 % .Convenient Coffee FactsSANICIP™ bag filter - top view3681 ny 09/09/02 16:58 Side 17Process control roompage 15page 14Process ControlControlling and monitoring a process line is of the essence for any operator. Niro’s proven process control system meets all requirements for safety, flexibility,and ease of use.Using standard hardware components, the process system enables you to:Supervise and monitor automaticplant start up, shut down, and cleaning proceduresWork with several product recipes in one systemLog every process activity for real-time and historical trendingInstrument and system specifications are selected in cooperation with our customer toensure the best hardware serviceduring the lifetime of the plant. CIP SystemCleaning, while necessary, can be anexpensive and time-consuming partof the process. Drawing on over 70years of experience in working withsanitary processes, Niro has developed a series of Cleaning-In-Place (CIP) systems.With features such as retractablenozzles in the main drying chamberas well as highly efficient processwater recovery, the CIP systemmakes a significant contribution to the profitability of the entire process line.A Partnership of SharingDuring engineering, commissio-ning/start-up and after-sales servicewe support our customers in theirefforts to increase process profit-ability. A partnership, where bothsides – Niro and the customer –learn about each other and shareexpertise and new experiences.A Partnership of SuccessNiro is a resource in every stage ofthe project. We have the experienceand know-how to ensure that allaspects are completed as smoothlyas possible, including: •••Available Sizes IC-125 IC-250 IC-500Green coffee input (kg/h) 275-375 550-750 1100-150010% H2ORoasted, ground coffee (hg/h) 240-330 480-650 960-13006% H2OYield % 39-52 39-52 39-52Instant coffee (kg/h) 125 250 5003% H2OAnnual production (t/year) 940 1875 3750Based on: 7,500 (h/year)with the Requirement Meeting Everythan Just Morea Plant…N I R O P O W D E R T E C H N O L O G YPlant sizesGeneral operational data for InstantCoffee (IC) plants are given in thetable. Available Sizes refer to theamount of kg that is produced each hour, i.e. an IC-250 plant will produce 250 kg of instant coffeeeach hour.Best in CIP and Process Control• Project financing• Product testing at our test station in Denmark• Process evaluation and optimisation• Design and engineering• Project management• Plant delivery, installation and commissioning• Training of plant operators• Technical service and supply of spare partsA unique range of technologies and the service to match – these are thereasons why choosing Niro means entering a partnership of success.C O N S U M P T I O N V A R I E S : I NN O R T H A M E R I C A , T H ER A T I O I S 4 . 4 % I N S T A N TC O F F E E T O 9 5 . 6 % F R E S H .I N E A S T E R N E U R O P E , I TI S 6 5 % I N S T A N T T O 3 5 %F R E S H , A N D I NA U S T R A L A S I A , T H E R A T I OI S 7 8 % T O 2 2 % .Convenient Coffee FactsSANICIP™ bag filter - top view3681 ny 09/09/02 16:58 Side 17COFFEEProcess Technologies for the Convenient Coffee IndustryCOFFEEProcessTechnologiesfor theConvenientCoffeeIndustryNiro Niro A/S • Gladsaxevej 305 • PO Box 45 • DK-2860 Soeborg • DenmarkTel: +45 39 54 54 54 • Fax: +45 39 54 58 00 • food.dairy@niro.dk • www.niro.comNiro A/SNiro is a world leader in industrialdrying, with spray drying, freeze drying, and fluid bed processing ascore technologies. The Niro companiesare part of the Process EngineeringDivision of the GEA Group.Process EngineeringDivisionA company of mg technologies groupBNA 828/GB 09/02 opusN I R O P O W D E R T E C H N O L O G YN I R O P O W D E R T E C H N O L O G YB L A C K A S T H E D E V I L , H O T A S H E L L , P U R E A S A N A N G E L , S W E E T A S L O V EArabic ProverbLEAVE THIS FLAP OPEN WHILE READING Process EngineeringDivision3681 ny 09/09/02 16:44 Side 1