Green coffee is roasted to perfection using state of the art Probat profile roaster which maps out a perfect roast taking into consideration the requirements of customer to bring out desired flavour and aroma.
Rotating cylinders containing the green beans and hot combustion gases are used in most roasting plants. When the bean temperature reaches 165 °C (329 °F) the roasting begins. It takes about 8–15 minutes to complete roasting.
After cooling, the beans are then ground finely. Grinding reduces the beans to 0.5–1.1-millimetre (0.020–0.043 in) pieces. This ground coffee is then then passed through extractors which uses water. Pressurized liquid water heated to around 175 °C (347 °F) is used for this process.
At this stage Aroma which is lost in high temperature is separated and captured separately.
The coffee concentration in the liquid is then increased by evaporation where soluble and volatile contents of the beans, which provide the coffee aroma and flavor, have to be extracted. At this stage the captured aroma is added back.
This is then Spray dried , coffee mixture which is now in a slush state is passed through nozzles into a hot air tower and collected as soluble powder. This spray druig process allows larger scale economic production, shorter drying times, and because it produces fine, rounded particles.
Completed in 5–30 seconds (dependent on factors such as heat, size of particle, and diameter of chamber).
Moisture content change: IN = 75-85% OUT = 3-3.5%.
Air temperature: IN = 270 °C (518 °F) OUT = 110 °C (230 °F).