Instant Coffee Manufacturing Process

Global Coffee Consumption

• Worldwide, approximately 2.25 billion cups of coffee are consumed daily.
• Instant coffee, a relatively recent innovation, was invented in 1901.

Coffee Bean Processing at the Factory

• Arrival and Storage

  • 70 tons of fresh coffee beans delivered daily from South America.
  • Up to 560 tons stored in a silo.

• Roasting

  • Beans filtered into large ovens.
  • Roasting temperature: 200 degrees Celsius.
  • Constant stirring ensures even roasting.

Coffee Brewing Process

• Grinding

  • Roasted beans ground into coarse powder using an industrial mill.

• Brewing

  • Powder brewed with steam and pressure in large coffee machines.
  • Produces 18,000 litres of coffee per hour.

Condensation and Extraction

• Coffee heated and condensed to form extract.
• Extract spread on a conveyor belt to next stage.

Freezing Process

• Freezing Hall

  • Workers wear thermal clothing due to temperatures of -50 degrees Celsius.
  • Extract frozen to at least -40 degrees Celsius.
  • Granules formed at the end of 30-meter conveyor.

• Sublimation

  • Frozen granules heated to 60 degrees Celsius in a vacuum.
  • Process vaporizes frozen water directly to steam, preserving aromas.

Packaging

• Freeze-dried granules stored in sacks.
• Jars filled, sealed, and labeled quickly on a conveyor.
• Factory produces 420 tons of instant coffee weekly.
• Represents only a fraction of daily global coffee consumption.

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