Flavourtech’s integrated extraction system (IES) has assisted coffee manufacturers to produce various premium coffee products on one continuous, automated processing line.
The IES was developed by Flavourtech to meet challenges faced by coffee manufacturers using outdated batch processing methods, including loss of freshly brewed coffee aroma, inefficient extraction of total solids, labour intensive and high-space requirement of batch processes, and lack of flexibility in producing products for different markets.
The installation of an IES overcomes these challenges. In one specific case, a customer in Asia was able to move from sixth position, in terms of market share, to equal leader in their territory within a few short years.
An IES allows manufacturers to produce a variety of premium full flavor products for the cold brew, ready to drink (RTD) and instant coffee markets. Built as a modular system, it can be inserted into existing process lines to make gradual improvements, or installed in its entirety.
As a semi or fully-automated system, the IES process can be operated with minimal staff. The easy-to-clean design allows different products to be processed with minimal downtime between runs, maximising factory throughput and efficiency.
The extraction module is quick and efficient and the system has been designed to minimise flavour loss by capturing the aroma of the raw material prior to it being subjected to high-temperatures. The fresh roasted aroma of ground coffee is captured at its peak, early in the process, and then added back to the extract or concentrate prior to packaging or drying, in the case of instant coffee.
Operating parameters can be readily adjusted to control the aroma profile. This enables manufacturers to precisely tailor the end product to the expectations of intended target markets, allowing them to satisfy more of their customers, thereby increasing sales and profits.
The IES is also able to meet the growing global interest in Cold Brew coffee products. Cold Brew coffee is generally produced by soaking ground roasted coffee beans for 10-14 hours at room temperature. Many manufacturers now prefer the IES over these standard batch type methods as its ability to continuously process a slurry of roasted coffee beans and water at room temperature allows it to produce a more desirable product quickly and easily.
Flavourtech technologies maximise the yield from the roasted beans used in the cold brew process. This allows both aroma and extract to be produced for a range of other RTD coffee products or even coffee powder.
The IES is so flexible that the same system can process tea (including black, green, and oolong) without any equipment changes, opening up new markets for manufacturers. The system has proven itself to be the right choice for customers who are focused not only on product quality but also on production costs and flexibility of use.
Contact Flavourtech today to find out more!