Confidential and proprietary information of the JACOBS DOUWE EGBERTS (JDE) group of companies. JACOBS DOUWE EGBERTS Rob Farr March 2018 The challenges of coffee processing: from nanogrammes to tonnes
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Confidential and proprietary information of the JACOBS DOUWE EGBERTS (JDE) group of companies.
JACOBS DOUWE EGBERTS
Rob Farr
March 2018
The challenges of coffee processing:
from nanogrammes to tonnes
Facts & Figures
A GLOBAL TEAM OF
MORE THAN 12000**
COFFEE CHAMPIONS
ANNUAL REVENUESOF MORE THAN
POSITION IN 28 COUNTRIES
ACROSS EUROPE, LATIN AMERICA
AND ASIA-PACIFIC
OUR BRANDS ARE ENJOYED
BY CONSUMERS IN OVER
120 COUNTRIES
€5BN
#1#2OR
A PORTFOLIO COMPRISING SOME OF THE MOST WELL-KNOWN COFFEE BRANDS
*Based on internal company data - Sep 2017 **Excludes businesses acquired during 2017
*
A Track Record Of Innovations
SENSEO PADS MACHINE PORTIONED ESPRESSOTASSIMO INTELLIGENT BREWER &
BEVERAGE RANGE
WHOLEBEAN INSTANT FOAM BOOSTER TECHNOLOGYSPRAY DRIED CREMA & PREMIUM
FREEZE DRIED TECHNOLOGIES
LIQUID TECHNOLOGYCOFFEE MACHINES FOR
PROFESSIONAL MARKETSAROMA LOCK ROAST & GROUND
First to launch aluminum capsules
in grocery retail
History of coffee
C10th
History of coffee
C10th
C14th
History of coffee
C10th
C16th
C14th
History of coffee
C10th
C17th
C16th
C14th
Our Heritage
8
1960
1978
1753
JACOBS DOUWE EGBERTS | OVER 260 YEARS OF EXPERIENCE
A portfolio comprising some of the most well-known coffee brands from around the world
18951853 1923
20041992 20011987
A theme in food processing
Coffee Farming: Varieties
Coffee production around the world
Coffea arabica Coffea canephora
• Richer, more refined flavour
• Lower in caffeine• Grows at higher altitude• Lower yields• More difficult to cultivate• Higher value product
• Stronger, more bitter flavour; high caffeine
• Grows lower altitude• High yields• Less susceptible to
diseases• Lower value product
75% of production is arabica.
Top producers: Brazil, Vietnam, Colombia, Indonesia, Ethiopia.
Arabica Robusta
Coffee Farming: Harvest and Initial Processing
Coffee grows as trees, up to several metres tall
Harvesting either by hand, or mechanically
Washed process
Semi-washed process
Dry method
Other methods exist; e.g. kopi luwak
Coffee Farming: Washed Process (High Altitude arabica)
Fermentation 12-36 hoursPulping DryingWashing
Need to remove flesh (pulp) and parchment of the coffee cherry, and end up with green beans
This process is used for the highest quality coffee, grown at altitude. It uses at least 1kg of water fore each kg of coffee cherries.
Corporate Responsibility
We are driven by our passion for coffee & tea, care for people and respect for the environment
Supporting coffee & tea farmers
At The
Source
Within Our
Company
For Our
Consumers
Reducing our environmental footprint
Everyone deserves the coffee they love
Coffee Processing at Banbury
Green beans
Banbury
Banbury
Coffee Processing at Banbury
Green beans
Roasting
Banbury
Coffee Processing at Banbury
Green beans
Roast whole beans
Roasting
Banbury
Coffee Processing at Banbury
Green beans
Roast whole beans
Roasting
Grinding
Banbury
Coffee Processing at Banbury
Green beans
Roast whole beans
Roast & Ground
Roasting
Grinding
Banbury
Coffee Processing at Banbury
Green beans
Roast whole beans
Roast & Ground
Roasting
Grinding
Industrial extraction
Banbury
Coffee Processing at Banbury
Green beans
Roast whole beans
Roast & Ground
Roasting
Grinding
Industrial extraction
Freeze-drying
Banbury
Coffee Processing at Banbury
Green beans
Roast whole beans
Roast & Ground
Instant coffee
Roasting
Grinding
Industrial extraction
Freeze-drying
Coffee processing: Roasting
Green beans Roast whole beans
Continuous drum roaster
Generates complex flavour chemistry, water vapour, CO2 and heat (exothermic reaction)
It is hard to instrument in detail during roasting, so process is currently poorly understood.
Fluidized bed
Process outcome
1CR
GB
City Full City 2CR
Vienna/LF Full French Charcoal
Microstructure of a coffee bean
Nano-grammereactor
Section through unripe coffee cherry
X-ray tomographic section through green bean
Simulation of single bean roasting
N.T. Fadai et al. “A heat and mass transfer study of coffee bean roasting”, Int. J. Heat & Mass Trans. 104 p787 (2017)
Multiphase flow is seen as crucial element missing in current models
Represented via volume fractions (porosity, water saturation S)
Based on mass & energy conservation equations between all phases
Spherical geometry is assumed
NB: no deformation of the coffee bean is considered at this time
Simulation of single bean roasting
Cells contain:• liquid water• water vapour• air• CO2
Mass transfer by pressure-driven porous flow through cell walls
Heat transfer by thermal conduction, advection and latent heat of vaporization
Liquid-vapour equilibrium depends on pressure
Cell walls degrade with a spectrum of activation energies
Simulation of single bean roasting
Under the approximation of vapour pressure set by the pure water steam table, there is a rather remarkable simplification
Set of 7 coupled partial differential equations
Roasting as a many-body problem
Mixing by avalanches
For example, the simple (and classic) geometric model of Metcalfe et al. [nature 364, 39 (1995)]
Mixing by avalanche
Rotation of drum
Many mechanisms of heat transfer!
• Exchange with a moving air-stream (forced porous convection)
• Bean-to-bean contact
• Conduction through walls of the roaster
Actually, this is freeporous convection, from Hewitt et al, [JFM 737 p205 (2013)]
Coffee Processing: Grinding
Roast whole beans
Grinding may raise the temperature of the coffee (to over 40°C), unless controlled
Roller grinder
Roast & ground
Most published work is in the area of wheat grinding
[C. Fang & G.M. Campbell, Cereal Chem., 79(4), p511 (2002)]
Behaviour strongly dependent on the plant histology: e.g. for wheat, have endosperm, germ, bran etc.
Some principles carry over to coffee
[C. Fang & G.M. Campbell, Cereal Chem., 79(4), p511 (2002)]
Whether bean is drawn in determined by particle size & coefficient of friction
Grinding with fluted rolls is more complex ...
Some principles carry over to coffee
Some principles carry over to coffee
Some principles carry over to coffee
Some principles carry over to coffee
[C. Fang & G.M. Campbell, Cereal Chem., 79(4), p511 (2002)]
G.R.
T μν = ρ U μU ν
Breakdown under deformation field
Breakdown under deformation field
Conclusions and outlook
Consider the “Grand old unit operations” of food processing• Decades old• Very complex• Optimised through bitter experience• Not well understood
We are in a unique position in history to unlock some of the hidden potential:• Advanced, pervasive and cheap measurement techniques• New modelling techniques• Computing power is cheap
Our Promise
Attribution of Images
Most images are used under commercial licence, or the GNU Free Documentation Licenence (version 1.2, published by the free software foundation). The following images are used under the “creative commons attribution-share alike 3.0 licence” (CC3) or the “CC BY-SA 4.0 licence” (CC4):
Picture of Coffea arabica berries (attributed to Forest & Kim Starr, 2009, CC3)Pictures of Coffea canephora 1&2 at Anakkulam (attributed to Jeevan Jose, 2010, CC4)Picture of ice block in Iceland (Andreas Tille, 2003, CC4)
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