The green coffee received in bags is classified and stored in respective storage areas. The storage building incorporates natural ventilation to maintain the beans at moisture levels between 9% and 11%. The cleaning operation removes various impurities such as fabric, dust and stones using specially designed machines.
ROASTING
Batch weighed green coffee beans are fed into the roasters. Roasting is carried out by circulating hot air. On completion, the roasted beans are quenched by water injection, followed by air cooling.
GRINDING
After roasting, the beans are ground to 2-3 mm with the help of special grinder in order to facilitate extraction.
EXTRACTION
Ground coffee is weighed and charged into a battery of seven extractors. Purified hot water at 180° C is passed through the charge under controlled counter current conditions, and then the extractors are emptied of spent grounds and refilled with fresh ground coffee in a sequence.
EVAPORATION
The liquid product is then divided into two parts. The initial volatile aroma extract is collected and stored separately, to be added back after the evaporation stage and before spray drying. This is to preserve the aroma in the product with the help of specially designed aroma recovery system.
SPRAY DRYING
After the extraction and clarification the product filtered first and then it flows through the positive pump to the Plate Heat Exchanger (PHE). The outlet of PHE goes to a high pressure pump and suction spray system. The final dried product is screened and collected in the tanks for inspection and the product parameters are maintained as per the desired standards.
AGGLOMERATION
This is an additional process by which Spray Dried powder is converted into Granules and milled. Steam and the milled powder pass through spraying nozzles to form granules in an Agglomeration tower under vacuum. The granules then pass through a fluid bed to maintain the moisture level before going into a vibrator screen to separate over-sized granules, desired size granules and fines.