3-in-1 coffee mixes is based on dry powder blending of Non-Dairy Creamer (NDC) powder, finely ground sugar and spray dried coffee powder. SPX FLOW’s processing technology concerning the former and latter is presented below.
Expertise in Non-Dairy Cream Processing
Creamer powder is often referred to as NDC, which consists of glucose syrup, vegetable oil and minor powder ingredients, such as sodium caseinate, sodium tri-polyphosphate, emulsifiers, flavours and salts. It is commonly used in beverages such as instant pre-mixed coffee beverages as a milk or cream substitute.
The NDC formulation is prepared by ingredient mixing under vacuum, followed by heat treatment, homogenisation and spray drying. These critical unit operations, enable end-product quality enhancement by avoiding entrapped air in the NDC formulation during mixing and permits uninterrupted operation of the heat treatment unit since CIP of one pasteurisation section is undertaking while the other duplex section is in operation. The continuous feed heat treatment allows extended spray dryer operation, limit product loss and promote a consistent powder quality.
The aforementioned critical unit operation integrates SPX FLOW components, key process equipment and in-house expertise i.e. sanitary automatic valves, pumps, Instant Flex-Mix, duplex pasteurisation and homogenisation by APV and Anhydro’s Triple-A multi-stage spray dryer.
From Coffee Bean to Powder – Achieving the Perfect Cup
Spray dried coffee powder is produced from concentrated coffee extract and SPX FLOW offers highly advanced coffee bean processing solutions, integrating technology and proven expertise.
Several factors impact the coffee extract quality such as the coffee bean grade and blend, roasting parameters, extraction technology and the extraction mode used. SPX FLOW’s process solutions maximise operational flexibility and improve product quality, while achieving the desired capacity.
In the extraction process, soluble solids and aromas are efficiently extracted, and the coffee aroma is carefully recovered to maximise the retention of the desired aromas.
After the extraction process, the coffee extract is clarified to remove sediments in a Seital centrifuge. The coffee extract, without aroma, is subsequently concentrated under low temperature conditions using an evaporator operating under vacuum.
The recovered aromas are mixed with the concentrated coffee extract to meet the desired taste profile. The standardised aroma-rich coffee extract can either be bottled as ready-to-drink beverages or further processed to either spray dried powder or freeze dried granules. Extraction is the key processing step to ensure the coffee extract quality and overall process feasibility. Another important feature of SPX FLOW’s coffee extract handling is the efficient removal of the undesired off-flavours which are formed by hydrolysis during extraction at high temperature. The off-flavours are removed by flash evaporation.
Unlike a conventional percolator, the SPX FLOW wide-body percolator design extracts finely ground roast coffee particulates to promote high-yield and recovery of the highly volatile aromas by steam stripping.
Indeed, the high yield which is obtainable using the SPX FLOW wide-body percolator design, translates into substantial monetary saving and improved aroma retention in the end-product.
Key Benefits of SPX FLOW’s Instant Coffee Processing Solutions
- Aroma stripping before extraction for premium aroma recovery;
- Multiple percolator designs;
- Short and wide-body design for both finely and coarse roasted and ground coffee to obtain high extraction yields and premium coffee extract quality;
- Conventional design for obtaining standard extraction yields and standard coffee extract quality;
- Different extraction modes depending on the desired coffee extract quality, and optimum use of water and steam;
- Second aroma recovery from the aroma-rich extract;
- Off-flavour removal after hydrolysed extraction mode;
- Extract clarification for sediment-free coffee extract;
- Different evaporator designs (multi-effect plate evaporators or multi-effect falling film tubular evaporators) with or without finisher;
- Multi-stage spray dryer or tall form spray dryer design, to meet specific end-product powder properties;
- Batch and continuous freeze drying systems, based on either a tray-system or belt-system.
Key No. 89797