Technical Solution for 3-in-1 Instant Coffee Production Line Needed
1. Process Flow Design
==Production Chain== (Starting from roasted coffee beans):
Roasted Coffee Beans → Grinding → Brewing → Concentration → Freeze-Drying → Mixing (Coffee Powder + Sugar + Creamer) → Quantitative Packaging (15g/sachet)
2. Key Equipment & Technical Parameters
2.1 Input Specifications
- ==Raw Material==: 200 kg unroasted coffee beans → 160-176 kg roasted beans (20-12% weight loss during roasting)
2.2 Grinding System
- ==Equipment==: Adjustable Turbo Coffee Grinder
- ==Parameters==:
- Capacity: 200-300 kg/h (matched to post-grinding process requirements)
- Particle Size: 500-800 μm (coarse grinding to prevent over-extraction)
- ==Auxiliary==: Vibratory Sifter (removes foreign particles)
2.3 Brewing & Concentration
Brewing Unit
- ==Equipment==: Continuous Coffee Extraction System with Heat Exchanger
- Temperature: 90-95°C
- Brewing Time: 5-8 minutes (recirculating water flow)
- Water-to-Coffee Ratio: 8:1 (roasted beans:water)
- Output: 1200-1400L coffee liquid (adjustable based on concentration needs)
Concentration Unit
- ==Equipment==: Vacuum Evaporator
- Concentration Ratio: 1:6 → 1:10 (20-30% solid content)
- Operating Temperature: 50-60°C (to preserve flavor)
2.4 Freeze-Drying System
- ==Equipment==: Industrial Batch Vacuum Freeze Dryer
- ==Process Stages==:
- ==Pre-freezing==: Cool concentrate to -40°C (ice crystal formation)
- ==Primary Drying==:
- Vacuum: 0.01-0.1 mbar
- Shelf Temperature: 30-50°C (sublimation phase)
- ==Secondary Drying==:
- Temperature: 60°C (remove bound water)
- Final Moisture: ≤3%
- ==Output==: 25-35 kg freeze-dried powder per batch (from 100-150 kg concentrate)
2.5 Mixing System
- ==Equipment==: 3D Motion Mixer (Food-grade stainless steel)
- ==Parameters==:
- Mixing Ratio: Coffee:Sugar:Creamer = 1:1:1 (adjustable)
- Batch Capacity: 200-300 kg (500L vessel)
- Mixing Time: 15-20 minutes (uniformity ≥98%)
- ==Auxiliary==:
- Sugar/Creamer Pre-treatment: Pulverizer (particle size matching)
- Magnetic Separator (metal impurity removal)
2.6 Packaging System
- ==Equipment==: Fully Automatic Vertical Form-Fill-Seal Machine
- ==Parameters==:
- Speed: 60-80 sachets/min (15g/sachet)
- Filling Accuracy: ±0.3g
- Material: Aluminum composite film (nitrogen-flushed preservation)
- ==Auxiliary==: Metal Detector, Checkweigher
3. Production Line Layout Recommendations
- ==Cleanroom Requirements==:
- Freeze-drying & Packaging Zones: Class 100,000 cleanroom
- ==Automation==:
- PLC-controlled parameters (temperature, humidity, mixing time)
- Data logging for traceability
- ==Energy Supply==:
- Freeze Dryer: 380V 3-phase power
- Steam Boiler: Supports concentration and CIP/SIP processes
4. Quality Control Protocol
| Parameter | Standard |
|---|---|
| Roasted Bean Moisture | ≤5% |
| Freeze-dried Solubility | ≥98% (no residue in hot water) |
| Mixing Uniformity | Caffeine SD ≤2% |
| Packaging Seal Integrity | Leakage Rate <0.1% |
5. Critical Recommendations
- ==Process Optimization==: Request coffee origin data to customize extraction parameters
- ==Regulatory Compliance==: Adhere to GOST R 51388-2019 (Russian instant coffee standard)
- ==Alternative Drying==: Spray-drying option available (40% cost reduction, slightly inferior flavor profile)
==Note==: A detailed technical task specification (daily output, factory dimensions, etc.) is required for final equipment selection and layout optimization.
End user may contact the solution provider for an onsite engineering survey in Moscow Oblast.