ARBA MINCH UNIVERSITY

SAWLA CAMPUS

COLLEGE OF ENGINEERING AND AGRO INDUSTRIAL TECHNOLOGY

DEPARTMENT OF FOOD TECHINOLOGY AND PROCESSING ENGINNERING

TITLE : PLANT DESIGN FOR THE PRODUCTION OF ROASTED COFFEE POWDER

BY: BETELHEM KARTA

RAMIT 415/11
 CHAPTER ONE

1.INTRODUCTION
1.1 Background

Coffee is the 2nd most traded commodity in the world market after petroleum. (Girma, 2011). It is
estimated that over 500 Billion cups are consumed every year. Ethiopia is the birthplace of coffee. As
much as this country is the homeland for the coffee plant, its people are also heavy consumers of
coffee. Over 50% of the coffee produced is consumed within total employment (Wikipedia, 2010). The
story of coffee has its beginnings in Ethiopia, the original home of the coffee . Coffee accounts for 60% of
exports, and 80% of plant,coffee arabica,which still grows wild in the forest of the highlands between
altitudes 1100 to 2200 meters with annual rainfall ranging from 1500 to 2500 mm, in slightly acidic soil
with a pH of 4.56-5. It is believed that Kaldi,an Abyssinian goatherd, who lived around 850 AD,
discovered coffee.

Major Coffee Growing Zone

‘Kaffa’, is produced in Kaffa, in parts of Illubabor, Wollega is also a place of their origin. For instance,
coffee traded as Cheffe, and Harrarge (consisting of 3 zones). A part from and Ludi, 2008). But so far, the
major areas include Kaffa, representing some of the distinctive coffee types, each area In Ethiopia,
coffee is grown almost everywhere. There are 600,000 hectares of land cropped with coffee. (Samual
Illubabor, Wollega, Gimbi, Sidamo, Gedeo, (including) Yirgachefee and other regions.

Modes of Coffee Production

semiforest coffee for about 35%, garden coffee for about 35% while state farms account for the rest.
Smallholder farmers produce 95% of Ethiopia’s coffee (Tafera and Tafera, 2013).farming
households .Furthermore, coffee plays an importantIt should, however, be noted here that the
contribution of Coffee has been part of their indigenous cultural traditions for of accelerated
deforestation. On the other hand, small coffee farms contribute about 90% of the country’s coffee,
Coffee is cultivated by 4 million preliminary smallholder under these systems is organic. (CSA, 2008).the
forest coffees has been dwindling as a consequence coffee, and plantation coffee. Forest coffee
accounts for 10%, production system: forest coffee, semi-forest coffee, garden and plantation for about
15% (5% government, 10% private) more than 10 generations. In Ethiopia, there are four types of of
total coffee production in Ethiopia. 95% of coffee produced role in social gathering and is important in
local consumption.

Worldwide Status of Coffee Production

Ethiopia is first Coffee is produced in more than 50 developing countries consumption per capita. About
65% of the world’s supply of five consumers are USA, Brazil, Germany, Japan and France, coffee is
Arabica, while Robusta currently makes up around estimated 100 million people (NRI, 2006). In 2005-06,
52% growth rate of 2.6% during the last 50 years (1963-2013) have supplying about a third of total
production (Figure 1). The top producers (Petit, 2007; Oxfam,2002) and employing an providing income
for approximately 25 million smallholder producers (Brazil, Colombia and Viatnam). Brazil total in Africa
and 7th in the world with 7.5 million bags annual of world’s production was accounted by main three
coffee while the Nordic countries have the world’s highest coffee 35%, compared to 25 years ago
(Scholer, 2004). An annual production of coffee (ICO, 2011).

Instant or soluble coffee

is a beverage that derived from brewed coffee beans. concentrated liquid. Instant coffee is
manufactured from coffee beans through the coffee is dehydrated into the form of granules or powder
through various manufacturing processes. It can be rehydrated using hot water to provide a drink similar
to brewed coffee. Besides, the instant coffee is also available in the form of series of process, including
roasting, grinding, extraction, concentration, drying and packing (Clarke and Macrae, 1987). It is
normally to produce a soluble powder or granules, either by spray-drying or freeze-drying technique.
1.2 Statement of the problem
It takes more time to prepare coffee for drinking and also need various equipments.Coffee which is
green bean has no long shelf life because it contain high moisture inside.Therefore,the objective of this
work is to allow consumer to make coffee in an ease and convenience way with out any equipment
other than cup and the preparation is simple and fast no time required. It also stays fresher and has long
shelf life because natural coffee or green bean lose there moisture during roasting.

1.3 Objectives
General objective

 To design roasted coffee powder production factory

Specific objective

1.4 Location and Site selection

Consideration Maximum point Yirgachefe Jimma Kaffa

factor

Raw material 100 80 90 70

availablity

Transport cost 100 80 80 60

Availablity of 100 50 70 50
labor

Availablity of 100 50 60 40
market

Availablity of 100 60 70 40
infrastructure

Government
influence

Banking and
financial
 institution

Location with link

Availablity of
skilled and non
skilled power

From the above table when we compare the three regions based on the factor from maximum point
100 jimma get 370 is choosen.
Chapter two

LITERATURE REVIEW

Instant coffee is a beverage that derived from brewed coffee beans. concentrated liquid. Instant coffee
is manufactured from coffee beans through the coffee is dehydrated into the form of granules or
powder through various manufacturing processes. It can be rehydrated using hot water to provide a
drink similar to brewed coffee. Besides, the instant coffee is also available in the form of series of
process, including roasting, grinding, extraction, concentration, drying and packing (Clarke and Macrae,
1987). It is normally to produce a soluble powder or granules, either by spray-drying or freeze-drying
technique.

Instant coffee powders in hot water deprives consumer of the full sensory experience that brewing roast
coffee affords. Substantional difference exist in the level,composition and sensory perception of aromas
released from filtered coffee brews versus those from prepared instant coffee beverages( Pollien
etal.1997;Sanz et Al.,2002). Aromatic essential oil pressed from roast coffee beans is commonly plated
onto spray dried or freez dried coffees to provide package headspace aroma to convey freshness upon
jar opening(Mishkin et al .,1964). Methods exist to even replenish headspace between openings by
plating onto microporous coffee particles (Saleeb and Hudak, 1981;Dwyer,1982;Hudak and
Saleeb,1984).Numerous method are known for controlling composition , strength,and sensory character
of aromatized coffee oils. Oil plating typically does not noticeably enhance perception or consumer
acceptance of beverage aroma, but can increase acceptance of cup flavor (Oliveira et Al.,2009).

Unit Operation for the process

1.Green bean treatment

Watering: Water the grean beans deeply about once (check the soil dryness).

Treatment:

a. Destroy affected plants immediately.

b. Remove any infected soil and replace with clean soil.

c. Use a barrier, such as mulch or plastic to keep infected soil away from plants.

2. Roasting

Coffee roasting is the process of heating the coffee cherry seeds to augment aroma and flavor and
ultimately increase solubility. It transforms the chemical and physical properties of green coffee beans
into roasted coffee product.

3.Grinding

The grind is the coarseness to which the coffee is ground, from coarse to pulverized. The coffee grind is
choosen based on the type of brewer being used. Coffee needs to be ground to increase the surface
area of the roasted beans. This enables the extraction of the soluble compounds that create the flavor
and aromas .

4. Extraction

It occur when hot water is poured over coffee grounds,causing desirable compounds such as
caffeine,carbohydrate,lipids and acid to be extracted from the grounds.

5.Aroma processing

It is a process for the recovery of aroma component from coffee . A slurry of coffee grounds in an
aquous liquid subjected to stripping for stripping aroma components from the slurry.

6.Spray drying

In this ground and extracted coffee concentrate is sprayed over a warm jet of air and processed into a
fine coffee powder .

7.Agglomeration

Coffee to which, after being dried , powder is added and then additional steam bealt or steam curtain
process is applied, which cause the particle to bind together,thus forming granules.

8.Freez drying

The coffee extract freez about -40c and cut into granules. The frozen granules then dried at low
temperature and under vaccum.

9.Packaging

Is the process of enclosing the instant coffee to protect it from sunlight, moisture, oxygen with the goal
of preserving the coffee taste and aromatic characteristics and also for ease of sale

.
Over all process flow of instant coffee manufacturing