Smoke condensate extraction system for medium and small-sized coffee roasters.

Description

/ 8 Smoke condensate extraction system for medium and small-sized coffee roasters. Field of invention

[001] The present invention relates to a “plug and play” device used for condensing coffee roasting smoke, among other things. This device is coupled to the outlet of a coffee roaster in order to collect the smoke generated by the roaster and transform it from a gaseous to a liquid state. This system is open to allow the non-condensed smoke to escape, thus not interfering with the roaster's airflow and maintaining the equipment's performance in its previous configuration. Fundamentals of the invention

[002] Coffee is a widely consumed fruit around the world, with the greatest interest focused on the roasted bean, essential for obtaining the popular coffee beverage. In Brazil, coffee cultivation began in Belém in 1727, originating from French Guiana. However, its production gained momentum in the Southeast of the country, especially in the states of Rio de Janeiro, São Paulo, and Minas Gerais.

[003] Coffee established itself as one of the main export products, playing a crucial role in the economy of the Empire. Its importance was such that it was even represented on the flag of Imperial Brazil. Today, coffee continues to be a beverage enjoyed by many consumers. However, the way this bean is produced and processed has undergone significant changes. Previously, production was mainly geared towards large companies, with farmers cultivating the fruit primarily for export. Brazilian domestic consumption of coffee was often limited to the sensory characteristics of bitterness.

[004] In the current scenario, coffee is experiencing the so-called 'Third Wave', characterized by a movement that promotes awareness of processes and values ​​other characteristics of the beverage. In this context, an artisanal process emerges in the production of specialty coffees, in response to a demand for quality. With the Petition 870250005464, dated 01 / 23 / 2025, page 53 / 60 / 8 As this wave advances, a significant increase in the emergence of small roasting companies and companies specializing in this sector is observed.

[005] Roasting is an extremely important process for coffee beans, as it is during this process that essential reactions occur, such as the Maillard reaction, Strecker degradation, caramelization, polyphenol degradation, and pyrolysis. In addition, there is the generation of compounds, whether volatile or not, and the distinctive characteristic of smoke generation.

[006] Smoke is one of the main factors driving the creation of the aforementioned equipment, a result of the rapid growth of coffee roasting plants. This growth brings with it challenges that need to be analyzed, including the tolerance limits for occupational exposure of roasters to the chemical agents present. Among these agents, volatile organic compounds stand out, such as furans, pyridines, pyrizines, and aldehydes, known for their high toxicity depending on the level of exposure. These compounds can be carcinogenic, cause toxicity, attack the central nervous system, affecting lung function, leading to flu, rhinitis, bronchitis, and worsening of chronic conditions such as asthma.

[007] Smoke from the coffee roasting process is a growing challenge for roasters, driving the search for solutions that minimize health risks to workers. The rapid growth of the coffee industry has led to an increase in production and, consequently, in the amount of smoke generated during the roasting process of the beans.

[008] By condensing volatile compounds, it is possible to transform them into a liquid form, facilitating their collection and subsequent treatment. This approach not only reduces the environmental impacts of pollutant emissions but also protects the health of workers by minimizing their exposure to harmful substances. Furthermore, the condensation of volatile compounds using the proposed equipment opens doors to a range of applications, such as in the production of flavorings, fragrances, pharmaceuticals, and industrial chemicals. This diversification of uses of Petition 870250005464, dated 01 / 23 / 2025, page 54 / 60 / 8 condensed compounds not only add value to the roasting process, but also contribute to the development of new sustainable products and markets.

[009] The new tools that contribute to the success of the Sustainable Development Goals (SDGs), which comprise the UN's 2030 Agenda, a global initiative aimed at ending poverty and protecting the environment and climate to ensure quality of life for the entire world population. The SDGs consist of 17 goals covering almost all aspects of sustainable global development, as well as actions against global climate change, zero hunger, increased food production, life below water and life on land, aiming to guarantee and promote responsible and sustainable consumption and production. Thus, the proposed device aims to support and bring the concept of the SDGs to coffee processing. Large roasters already have systems that filter smoke, reducing their emissions.Thus, this awareness becomes equally crucial for medium and small coffee roasters, as it represents a way to add value to the products sold and to explore new applications for the condensed product, making the business more aligned with the Sustainable Development Goals (SDGs).

[0010] In the aforementioned scenarios, the present invention aims to introduce equipment for processing coffee roasting, characterized by its ease of use and reduced cost. One of its main features is the release of smoke condensate, allowing it to be coupled to any roaster at the smoke line outlet of the roasting process.

[0011] In recent years, some work has been developed aimed at collecting smoke and recovering volatile compounds, such as the implement patented in 2005 (US6942887B1) proposing a roaster in which the smoke is passed through a filtering sieve that blocks the emission of particulate matter, but not volatile compounds. However, the invention is a roaster with particulate matter filtering.

[0012] In 2013 (EP2509433B1) the invention was given for a process for the recovery of volatile aromatic compounds from a plant material, characterized by the plant material being placed in a dryer where the moisture from the incoming gas is removed. The gases of Petition 870250005464, dated 01 / 23 / 2025, page 55 / 60 / 8 exhaust from the dryer comes into contact with water vapor, which can contain at least 50% evaporated water by mass, at a temperature of 95°C to 120°C, to form a gaseous mixture. Then the gaseous mixture is condensed to recover a condensate containing volatile aromatic compounds. However, this implement uses coffee beans.

[0013] In 2017, patent BR102017001532-7 A2 was registered, entitled PROCESS FOR PRODUCING EXTRACT IN THE ROASTING OF COFFEE BEANS AND PRODUCT OBTAINED. This patent describes a process for obtaining a liquid extract from the smoke generated during the roasting of coffee beans, using water spraying to capture specific compounds. The method results in an extract rich in carbohydrates, with emphasis on the capture of carbon dioxide (CO2) present in the smoke. Despite this, the technology has significant limitations. Firstly, it does not address in detail the condensation and recovery of volatile compounds from the smoke, which could add value to the extract, and its application is limited to specific use in coffee. In addition, the walls of the system frequently contaminate the condensate, restricting its use mainly to fertilization.The system also lacks adequate cleaning mechanisms, which compromises its functionality and results in continuous water consumption during the extraction process. Finally, the technology is not easy to install (plug-and-play), requiring the construction of a specific structure at the implementation site, which can present operational challenges and high costs.

[0014] In 2020, patent BR112020008187-6A refers to systems and methods for capturing and collecting vapor and smoke. It is a method used to capture vapor, smoke, and fumes by dissolving or mixing them with solvents. However, this patent uses a liquid solvent to retain volatile components of the smoke and is a closed system, which, during the roasting process, would negatively affect the process.

[0015] In 2021, the invention Apparatus and Method for Roasting Coffee Beans (BR112021005442A2) describes a method for roasting coffee beans and a smoke treatment unit, intended to control contaminants released during the roasting process and protect the environment. However, the device consists Petition 870250005464, dated 01 / 23 / 2025, pp. 56 / 60 / 8 in a roaster coupled to a smoke collector that, although capturing some harmful constituents, allows aroma to escape and impairs airflow during production, compromising the quality of the roasting process. Furthermore, it does not collect the compounds for future use. Despite being environmentally sound, it cannot be considered entirely sustainable, as it does not utilize a valuable byproduct and impairs roasting quality, making the production of high-quality specialty coffees unfeasible. Brief description of the drawings

[0016] Figure 1 presents a colored isometric perspective with transparency of the electronics and compressor system support housing of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: inlet connection of the smoke flow stages (1); electronics and compressor system support housing (2); condensate reservoir (3); system support structure (4); heat transfer condenser grid (5); system outlet duct (6); compressor system control panel 28 (7); solenoid valve opening button (8); system switch (9); emergency button according to NR12 (10); reservoir inspection and cleaning door (11); outlet cooling evaporator coil (12); high power dissipation tube with fins (13).

[0017] Figure 2 presents the isometric perspective of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: Coolant lid (14); coolant reservoir (15); corrugated duct (16); compressor system control panel 26 (17); condenser (18).

[0018] Figure 3 shows the front view of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: Inlet connection of the smoke flow stages (1); corrugated duct (16); compressor system control panel 26 (17); internal gas flow alteration fins Petition 870250005464, dated 01 / 23 / 2025, page 57 / 60 / 8 (19 and 20); removable condensate outlet cone for inspection, cleaning and maintenance (21); condensate opening and outlet solenoid valve (22).

[0019] Figure 4 shows the left side view of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: Condenser (18); smoke passage guide (23); refrigerant liquid passage coil (24).

[0020] Figure 5 shows the front view of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: Condenser (18); fan (25); larger refrigeration compressor (26); refrigerant pump (27); smaller refrigeration compressor (28).

[0021] Figure 6 shows the front view and detail of the corrugated and smooth duct of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: corrugated duct (16); smoke passage guide (23); refrigerant liquid passage coil (24); smooth duct (29).

[0022] Figure 7 shows the front view and detail of the refrigerant reservoir coil of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: Heat transfer condenser grid (5); refrigerant reservoir (15); refrigeration evaporator coil (30).

[0023] Figure 8 shows a top cutaway view highlighting the particle atomizing piezoelectric of the SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL ROASTERS. In it, one can observe: the particle atomizing piezoelectric (31). Petition 870250005464, dated 01 / 23 / 2025, page 58 / 60 / 8 Description of the invention

[0024] The present invention relates to a system for extracting liquid condensate from the smoke generated in the roasting process. The extracted liquid has wide applicability, and can be used in the food, medical, and agricultural sectors (as fertilizers or soil improvers), in the formulation of cosmetics, and in other industrial products that take advantage of its specific chemical properties.

[0025] The present invention is characterized as a plug-and-play type of agricultural equipment, designed to offer ease of integration. Its main innovation lies in its ability to couple to any roaster with a smoke outlet tube, without the need for changes to the roaster's exhaust settings. In addition, it has a flexible tube that simplifies the coupling process, ensuring greater practicality and versatility in installation.

[0026] The unit is composed of an integration of components designed to ensure efficiency and versatility. Among them, the following stand out: the support housing for the electronic systems and compressors, the reservoir for condensate storage, the condenser grid for heat transfer, and the high-power tube with fins for heat dissipation. In addition, the system is equipped with control panels that facilitate operation, solenoid valves for automated condensate flow management, and flexible ducts that simplify installation and smoke flow direction.

[0027] It is equipped with an ultrasonic system based on piezoelectric technology, designed to atomize particles and optimize condensate extraction efficiently.

[0028] The system is designed to meet the needs of medium and small-sized roasters. For medium-sized roasters, it is suitable for machines with a capacity of approximately 20 kg per roast. For small-sized roasters, it offers a compact and efficient solution, also adapting to smaller-scale operations, adding value to the production process through the reuse and optimization of resources. Petition 870250005464, dated 01 / 23 / 2025, pages 59 / 60 / 8

[0029] Regarding the coupling, the system was developed to not compromise the operation of the roaster, preserving its operational characteristics. It does not interfere with the system's airflow, avoiding any negative impact on the coffee roasting process or other operations. Petition 870250005464, dated 01 / 23 / 2025, page 60 / 60

Claims

1 / 2 CLAIMS SYSTEM FOR EXTRACTING CONDENSATE FROM COFFEE SMOKE AND OTHERS, APPLIED TO MEDIUM AND SMALL-SIZED ROASTERS 1. System for extracting condensate from smoke, applied to medium and small-sized roasters, characterized by comprising: (a) a support housing (2) for the electronic systems and compressors; (b) a condensate reservoir (3) configured to store the liquid extracted from the smoke; (c) a condenser grid (5) for heat transfer; (d) a high-power finned tube (13) for heat dissipation; (e) an ultrasonic system based on piezoelectric technology (31) to atomize particles and optimize condensate extraction; (f) control panels (7, 17) that allow automated operation of the system; (g) solenoid valves (22) for managing condensate flow; (h) flexible ducts (16) configured to direct the smoke flow without compromising the operation of the roaster.

2. The system according to claim 1, characterized by being compatible with medium-sized roasters, with a capacity of approximately 20 kg per roast.

3. The system according to claim 1, characterized by being adaptable to small-scale roasters, offering a compact and efficient solution for smaller-scale operations.

4. The system according to claim 1, characterized by its plug-and-play design, allowing integration with existing roasters without the need for changes to the exhaust configurations. Petition 870250005464, dated 23 / 01 / 2025, page 51 / 60 2 / 2 5. The system according to claim 1, characterized by having a refrigeration evaporator coil (30) integrated into the refrigerant liquid reservoir (15), ensuring greater thermal efficiency in the condensation process.

6. The system according to claim 1, characterized by including a removable condensate outlet cone (21), designed to facilitate inspection, cleaning and maintenance.

7. The system according to claim 1, characterized by preserving the airflow of the roaster, without negatively impacting the coffee roasting process. Petition 870250005464, dated 01 / 23 / 2025, pp. 52 / 60

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