Spray-dried coffee product and method of manufacturing same

Abstract

To provide a spray-dried coffee product and a production method thereof.SOLUTION: The present invention relates to a method of producing a coffee powder, the method comprising: a) providing an aqueous coffee extract comprising 30-55 wt.% of soluble coffee solids and 1-10 wt.% of oil, where the aqueous coffee extract consists of water and coffee-derived components; b) subjecting the aqueous coffee extract to a two-stage homogenization process to obtain a homogeneous coffee extract, where the first stage is conducted at 200-1000 bar and the second stage is conducted at 10-100 bar; and c) spray-drying the homogeneous coffee extract.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a process for providing an improved spray-dried coffee product and to the spray-dried product, in particular to a spray-dried coffee with an improved sensory profile obtained by spray-drying an oil-rich, homogeneous coffee extract. [Background technology]

[0002] It is well known to extract roast and ground coffee with water to obtain a coffee extract with a high coffee solids content. It is further known to dry such extracts by spray drying or freeze drying to obtain a soluble beverage powder. This beverage powder can then be reconstituted with hot water at the consumer's convenience to obtain a coffee beverage. It is desirable for such homemade coffee beverages to have a taste similar to that of coffee shop beverages.

[0003] Industrial production of soluble coffee products involves higher temperatures and pressures than coffee shop brew systems. This allows for a higher yield from the beans, and therefore higher profitability, but has the side effect of potentially imparting undesirable processed flavor notes to the coffee. To avoid this, a number of techniques have been employed, including aroma capture methods to ensure flavor molecules are preserved during the initial cold extraction step.

[0004] An example of a conventional coffee extraction process involves the following steps: Raw coffee beans are roasted to a desired roast range and ground to a particle size of 2-3 mm. This is then subjected to a column extraction process with a first step at approximately 150°C and a second step at a higher temperature of approximately 185°C. The coffee extract washed from the beans at each extraction step is combined, concentrated, and dried. The process is semi-continuous, using multiple extraction columns.

[0005] European Patent No. 0826308 discloses a process for countercurrent extraction of soluble coffee solids. Soluble coffee solids are extracted from roasted and ground coffee in a first extraction stage using a primary extraction liquid at a temperature of 80°C to 160°C. Soluble coffee solids are then extracted from the partially extracted grounds in a second extraction stage using a secondary extraction liquid at a temperature of 160°C to 190°C, the coffee grounds having at least 25% by weight of soluble coffee solids extracted therefrom. The coffee grounds from the second extraction stage are discharged and thermohydrolyzed in a hydrolysis stage at a temperature of 160°C to 220°C for 1 to 15 minutes. Soluble coffee solids are extracted from the hydrolyzed coffee grounds in a third extraction stage using a tertiary extraction liquid at a temperature of 170°C to 195°C to provide extracted coffee grounds and a hydrolyzed coffee extract. A soluble coffee product is obtained containing at least 30% sugars, including less than 1% furfural derivatives, less than 4% monosaccharides, less than 10% oligosaccharides, and at least 19% polysaccharides, the sugars having a weighted average molecular weight greater than 2000 units with a polydispersity index greater than 3.

[0006] European Patent No. 0916267 discloses a process for continuously extracting water-soluble solids from solid particles containing them, such as roast and ground coffee, to provide an extract product in one or more extraction stages. In each extraction stage, a slurry containing the particles to be extracted and the extract is introduced into an extraction reactor, e.g., immediately above a solid-liquid separator, to form an upwardly moving packed bed. The particles are scraped from the packed bed to define the upper surface of the packed bed. An extract liquid is introduced into the extraction reactor above the upper surface of the packed bed. A portion of the extract liquid percolates through the packed bed to extract water-soluble materials from the particles in the packed bed, forming the extract. The remaining portion of the extract liquid captures the particles scraped from the packed bed to provide a spent particle slurry. The spent particle slurry is removed from the extraction reactor. The extract is removed from below the packed bed, and at least a portion of the extract forms the extract product. The extraction stages may be separated by one or more solubilization stages.

[0007] European Patent No. 1069830 discloses a process for recovering aroma components from coffee. A slurry of coffee grounds in an aqueous liquid is stripped to strip the aroma components from the slurry. Stripping is performed using a gas in a substantially countercurrent manner to provide an aroma gas containing the aroma components. The aroma components are then recovered from the aroma gas. The aroma components may be added to a concentrated coffee extract prior to drying the extract. The resulting coffee powder has significantly increased and improved aroma and flavor and contains higher concentrations of furans and diketones.

[0008] U.S. Patent No. 3,682,649 discloses cold water pressure extraction of roasted coffee, either whole bean or ground, to obtain a high quality coffee extract and a partially extracted coffee that can be further processed. The coffee extract can be dried to obtain a superior soluble coffee. The partially extracted coffee can be further extracted by standard infusion techniques or dried and used as regular roast and ground coffee.

[0009] U.S. Patent No. 3,652,292 discloses the production of instant coffee powder containing soluble coffee solids prepared by extraction in an aqueous medium to which wet-ground colloidal particles of roasted or extracted roasted coffee are added. The colloidal particles represent approximately 3% to 40% by weight of the total weight of the coffee product. The colloidal particles are stabilized against agglomeration by adjusting the pH to not exceed 5.2, and the particles are placed in a dry soluble coffee solids to form an instant coffee product with freshly brewed coffee aroma, flavor, and turbidity.

[0010] EP 1795074 relates to a method for providing a concentrated coffee extract that is rich in aroma components released when roasted coffee beans are ground, and in which the amount of coffee oil can be controlled depending on the application and purpose, and a process for industrially producing the same. According to the present invention, the above object is achieved by separating an aroma component-containing distillate, a coffee oil-containing liquid, and a coffee extract from a slurry obtained by wet grinding roasted coffee beans, concentrating the coffee extract, and then adding back the aroma component-containing distillate and the coffee oil-containing liquid.

[0011] U.S. Patent Application Publication No. 2015 / 296829 describes a method for surface treatment of soluble coffee to improve its flavor and aroma. The method involves sequentially adding 0.5 to 4% by weight of coffee oil, followed by 1 to 3% by weight of water, onto the surface of existing soluble coffee powder.

[0012] European Patent No. 0916267 discloses a method for extracting coffee from roasted and ground coffee beans. In particular, the product obtained from the extraction reactor 10 through the lower outlet 30 is a liquid coffee extract 32. This is divided into a recycled coffee extract 42 for slurrying fresh coffee grounds and a product coffee extract 20 (paragraph

[0026] ). The liquid exiting through the lower outlet 30 has already passed through a screen 14 that retains coffee solids.

[0013] US Patent No. 3,361,571 relates to a method for obtaining a decaffeinated coffee product.

[0014] EP 1795074 relates to an extraction process for providing a concentrated, aroma-containing, clarified coffee extract. The key to this process is low-temperature wet-milling extraction. As a result of the low-temperature operation, the extract contains low levels of mannans, which cause sedimentation and contribute to the formation of insoluble coffee fractions. The extract is then subjected to three clarification steps: coarse filtration, centrifugation, and microfiltration.

[0015] Because the production of liquid (i.e., aqueous) coffee extracts and dried soluble coffee products differ in flavor compared to freshly brewed coffee beverages in a coffee shop environment, there is a constant need to improve production methods to achieve improved products. One common approach to improving the flavor of dried soluble coffee products is to add finely ground roasted coffee particles to the coffee extract before drying. The inclusion of such particles is typically controlled to avoid excessive sediment in the beverage, but generally has a beneficial effect on the product's flavor. The presence of small particles can also contribute to the observed mouthfeel.

[0016] GB Patent No. 1399650 discloses improving the agglomeration of water-soluble instant food powders.

[0017] U.S. Patent Application Publication No. 2006 / 0035000 discloses a soluble coffee product having improved flavor and aroma, which includes soluble particulate coffee and unaromatized coffee oil, the process being via solvent extraction of the coffee oil or expression of the coffee oil from the beans under pressure.

[0018] US Patent No. 2015296829 relates to a method for adding coffee oil to the surface of already formed coffee powder to improve the aroma of the product.

[0019] US Patent Application Publication No. 2014 / 106055 relates to a technique for producing ultra-concentrated liquid coffee that is shelf stable at ambient temperature without the need for refrigeration or freezing.

[0020] WO2020136146 discloses an instant coffee composition for forming a coffee beverage, the composition comprising at least 6% by weight of an insoluble coffee sediment fraction, the insoluble coffee sediment fraction containing no more than 1% by weight of arabinose as analyzed after acid hydrolysis. It is therefore desirable to provide improved methods for producing coffee products, improved coffee products, and / or to address at least some of the problems associated with the prior art, or at least to provide commercially available alternatives thereto. [Prior art documents] [Patent documents]

[0021] [Patent Document 1] European Patent No. 0826308 [Patent Document 2] European Patent No. 0916267 [Patent Document 2] European Patent No. 1069830 [Patent Document 2] U.S. Patent No. 3,682,649 [Patent Document 2] U.S. Patent No. 3,652,292 Summary of the Invention [Means for solving the problem]

[0022] According to a first aspect, there is provided a method for producing coffee powder, the method comprising: a) providing an aqueous coffee extract comprising 30-55% by weight of soluble coffee solids and 1-10% by weight of oil, the aqueous coffee extract consisting of water and coffee-derived components; b) subjecting the aqueous coffee extract to a two-stage homogenization process to obtain a homogenous coffee extract, the first stage being carried out at a pressure of between 200 and 1000 bar and the second stage being carried out at a pressure of between 10 and 100 bar; c) spray drying the homogeneous coffee extract. DETAILED DESCRIPTION OF THE INVENTION

[0023] The present invention will now be further described. In the following sections, different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect(s), unless expressly stated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature(s) indicated as being preferred or advantageous.

[0024] The present invention provides a method for producing coffee powder, particularly spray-dried coffee powder. Spray-dried coffee powder is considered an "instant" coffee product because it forms a beverage substantially immediately upon addition of hot water (e.g., 80-95°C). Such products can be complemented by the addition of small amounts of finely ground roast and ground coffee to improve flavor or appearance, as is well known in the art. This can be added before or after the spray-drying process.

[0025] This application refers to "solids." These are the materials remaining after all the water has been removed. Thus, if you take a coffee beverage and remove the water (by evaporation), you are left with coffee solids. These coffee solids include soluble coffee solids and insoluble coffee solids. Insoluble coffee solids include roast and ground coffee materials and coffee oil. A further distinction is made herein about the insoluble coffee sediment fraction, which is the non-oily portion of the insoluble coffee solids.

[0026] Preferably, the aqueous coffee extract comprises 35-70 wt.% total solids (i.e., soluble and insoluble coffee solids), and more preferably, the aqueous coffee extract contains 45-55 wt.% total solids. Below 35 wt.% total solids, the spray drying process is inefficient due to the large amount of water that must be removed. Above 70 wt.%, the solids level may be so high that spray drying by the spray drying method becomes difficult.

[0027] The method includes preparing an aqueous coffee extract containing 30-55% by weight soluble coffee solids and 1-10% by weight oil, the aqueous coffee extract consisting of water and coffee-derived components. The coffee solids primarily contain soluble coffee solids, but also contain a portion of insoluble coffee solids, including coffee oil. Desirably, the insoluble coffee solids contain a non-oil insoluble coffee sediment fraction, which can be obtained by supplementing the aqueous coffee extract with finely ground roasted coffee material. Alternatively, the insoluble coffee sediment fraction is naturally obtained from the manufacturing process. As shown in the examples, small amounts of insoluble material are present in most instant coffee products.

[0028] Preferably, the aqueous coffee extract contains 1.5-5% by weight of coffee oil, more preferably 2-4% by weight of coffee oil. As shown in the examples, it is unusual for soluble coffee to contain such high levels of oil.

[0029] Preferably, the aqueous coffee extract contains 45-55% by weight soluble coffee solids, as this means that less water needs to be removed during drying, which improves processing efficiency.

[0030] Preferably, the aqueous coffee extract is obtained by a new extraction process described in International Patent Application No. PCT / EP2019 / 086859, filed December 20, 2019, the entire contents of which are incorporated herein by reference. This process inherently provides an aqueous coffee extract containing a high amount of coffee oil, as described below. In contrast, most known roast and ground coffee extraction techniques produce extracts with low levels of oil, either intentionally to avoid products that form an oily film on the surface of the beverage, or as an inevitable consequence of the processes employed. In addition, we have found that this process inherently provides a non-oily, insoluble coffee sediment fraction that improves body and flavor, without the need for supplemental extract.

[0031] Advantageously, therefore, the method does not require a separate step to obtain coffee oil, as it does not rely on the addition of a separate oil source, such as that obtained by expression (squeezing and pressing of dried beans) or solvent extraction (such as with CO or organic solvents). Rather, it has been found that when coffee beans are very finely ground (<600 micrometers), high levels of coffee oil are naturally released when they are subjected to slurry extraction. Thus, the preferred method used herein does not have any step of adding coffee oil to the aqueous coffee extract.

[0032] While the process of the first aspect described herein avoids the presence of an oily surface film, the addition of the homogenization step discussed herein provides additional unexpected benefits. In particular, the sensory profile, including taste and mouthfeel, is altered and improved. Without being bound by theory, it is speculated that the stable oil-water emulsion produced serves to better protect the desirable aroma compounds in coffee during the spray-drying process. Furthermore, the stable oil-water emulsion allows for a high level of aroma to be added back to the coffee, thereby resulting in a highly aromatized product. That is, it has been surprisingly discovered that coffee oil not only protects the aroma in coffee, but also protects a large portion of the volatile aroma compounds added to the spray-dried coffee extract.

[0033] The method further includes subjecting the aqueous coffee extract to a two-stage homogenization process to obtain a homogenized coffee extract, the first stage being conducted at 200-1000 bar and the second stage being conducted at 10-100 bar. Homogenizers are well known in the beverage industry and are used to stabilize emulsions, particularly in dairy processing. Providing a two-stage process is particularly preferred, as a single stage tends to cause oil aggregation and cluster formation. Furthermore, the use of a high-pressure stage followed by a low-pressure stage results in a more stable emulsion. The inventors have found that a homogenizer is the only way to achieve the desired very fine oil-in-water emulsion required for a beneficial end product.

[0034] Preferably, the first stage is carried out at 500-1000 bar, e.g., 600-800 bar. It has been found that these higher ranges in the first step result in smaller average (D50) oil droplet sizes with greater stability. Preferably, the second stage is carried out at 10-50 bar. It has been found that these processing conditions maximize emulsion stability. Homogenization occurs very quickly for a given portion of the extract, and under the specified conditions, the emulsion remains stable for hours, if not days.

[0035] The coffee extract is preferably homogenized to have a D50 oil droplet size of less than 8 micrometers, preferably less than 7, more preferably less than 5, and most preferably less than 4, such as preferably 1-7 micrometers, most preferably 1-5 micrometers, more preferably 2-4 micrometers, and more preferably 2.5-3.5 micrometers. The inventors have found that oil droplets in this size range remain preserved in the reconstituted beverage obtained from the spray-dried powder, imparting an improved perception of creaminess. In contrast, larger oil particles resulted in the sensation of a less full-bodied (i.e., waterier) beverage. The droplets also remained preserved during storage of the extract, eliminating the need to restrict the specific process applied prior to spray drying.

[0036] The coffee extract is preferably fed to the homogenizer at a temperature of 40-90°C and a gauge pressure of 1.5-10 bar, which is necessary to ensure that the high solids extract can be pumped without temperature degradation of the composition.

[0037] Finally, the method involves spray-drying the homogeneous coffee extract. Spray-drying processes are known in the art. The product is a spray-dried instant coffee powder. Exemplary spray-drying conditions are 40-90°C and 20-500 bar. The moisture content of the product is preferably 1-5% by weight, e.g., about 3% by weight.

[0038] Preferably, the homogenized extract is transferred to the spray dryer immediately without storage. This allows a single high-pressure pump to be used to drive the homogenization and spray-drying steps, resulting in energy and processing efficiencies. Homogenizer designs that can be driven by a single pump are known in the art. Preferably, the extract is spray-dried within 5 minutes, preferably about 1 minute, of homogenization.

[0039] Before spray-drying the coffee, it may be subjected to a gas injection process. This can be done before or after the homogenization process and has no particular effect on the product. This increases the porosity of the product, thereby decreasing the density of the final product. An example of a gas injection method is described in U.S. Pat. No. 5,882,717. The gas can be added in any suitable amount and at any pressure, with pressures ranging from 1 to 500 bar (gauge pressure) being known. A preferred pressure is in the range of 10 to 100 bar, e.g., 40 bar (gauge pressure). The addition of gas to the product allows for a product with high oil and aroma, along with a low density (especially CO2) or high product crema (especially N2). Most preferably, the injected gas is nitrogen, which provides the crema.

[0040] As will be appreciated, spray drying is one of many techniques, including freeze drying, used to produce coffee powder. Freeze drying involves taking fresh coffee extract, cooling it to approximately -40°C, and then sublimating the water. This results in an open-pore product. In contrast, spray drying involves spraying the fresh extract into the top of a spray-drying tower along with a hot circulating gas. Therefore, drying of spray-dried powder is typically faster and hotter, which makes the extract more susceptible to degradation. The product also tends to have fine, closed pores.

[0041] Spray drying is preferred because of the processing conditions, allowing for larger quantities to be processed more quickly. As a result, there is a general prejudice among consumers that spray-dried coffee may have less true coffee aroma. This is presumably due to the loss of volatile coffee solids during the more severe drying process. Therefore, freeze-dried products are generally considered to be more premium and are expected to have a better sensory profile.

[0042] However, the inventors have found that by preparing an aqueous extract with a high oil content that is subjected to homogenization prior to spray drying, an improved product can be obtained, particularly when the extract is supplemented with the recovered aroma fraction, as the aroma fraction appears to be unexpectedly retained through the drying process. As a result, the inventors have been able to obtain a spray-dried coffee product with a flavor and mouthfeel that matches and even exceeds that of freeze-dried coffee powder.

[0043] Thus, according to a preferred embodiment, the aqueous coffee extract is an aromatized coffee extract, i.e. the aqueous coffee extract comprises an aroma fraction obtained from fresh roast and ground coffee.

[0044] Aroma recovery processes are known in the art and are sometimes referred to as steam stripping. In a typical steam stripping process, a column is packed with roasted and ground coffee (average particle size 2-3 mm), which is moistened with a small amount of water (approximately 0.5% by weight of the beans) before contacting with steam. The steam distillate is then recovered as the aroma fraction. This process is preferably carried out so that the aroma stripped fraction constitutes 1-15% by weight of the starting weight of the roasted and ground coffee (and water). That is, the stripping process removes and recovers the volatile components that make up a weight fraction of the original coffee. Preferably, the stripping process is carried out so that the aroma stripped fraction constitutes 5-12% by weight of the starting weight of the roasted and ground coffee (and water), more preferably about 10% by weight.

[0045] Another method for aroma recovery involves passing steam through a slurry of more finely ground coffee beans, as described below. This process is preferably carried out so that the aroma stripping fraction constitutes 1 to 15% by weight of the starting roast and ground coffee-containing slurry. Preferably, this process is carried out so that the aroma stripping fraction constitutes 5 to 12% by weight, more preferably about 10% by weight, of the starting slurry weight. This level of recovery by either technique yields the majority of the volatile flavor and aroma compounds without requiring excessive water recovery.

[0046] The steam distillate obtained from any of the above processes contains a significant amount of water, so that coffee aroma components may represent only 0.1-5%, preferably 1-3%, by weight of the coffee aroma fraction, and therefore when added to aromatize the coffee extract, it has the effect of diluting the coffee solids.

[0047] Preferably, the method for obtaining an aromatized coffee extract comprises: (i) providing roasted and ground coffee; (ii) contacting roast and ground coffee with water to form a coffee composition; (ii) subjecting the coffee composition to an aroma separation step to recover a coffee aroma fraction and to form dearomatized roast and ground coffee, wherein the aroma separation step recovers 1 to 15% by weight of the coffee composition as the coffee aroma fraction; (iii) subjecting the dearomatized roast and ground coffee to one or more aqueous extraction steps to obtain an intermediate coffee extract having a coffee solids content of 35 to 70% by weight; (iv) adding the coffee aroma fraction to the intermediate coffee extract to form an aromatized coffee extract.

[0048] The roasted and ground coffee preferably comprises, or optionally consists of, Arabica coffee beans, since Arabica coffee beans naturally contain higher levels of coffee oil. When using conventional methods to obtain coffee extracts, the roasted and ground coffee has an average particle size of about 2-3 mm. As this increases the amount of oil released, as described below, the roasted and ground coffee preferably has an average particle size of 100-600 micrometers.

[0049] The de-aromatized roast and ground coffee is subjected to one or more aqueous extraction steps to obtain an intermediate coffee extract having 35-70% by weight coffee solids (i.e., soluble coffee solids, coffee oil, and any insoluble coffee fractions), preferably 45-65% by weight coffee solids. As noted above, higher solids levels are preferred because subsequent complementation with coffee aroma has a dilution effect. It should be noted that the extraction step also involves some kind of concentration step, such as evaporation in an evaporator, to achieve these solids levels. Such steps are routine in extraction and spray-drying processes to obtain coffee powder.

[0050] Extraction processes are known in the art, and preferably involve subjecting the coffee to multiple steps, each of which recovers a different coffee extract fraction. Each successive step involves higher temperatures, which recovers different coffee components and improves the overall yield. The sequential steps allow heat-sensitive components to be recovered separately from components that require more severe conditions to hydrolyze into soluble coffee components.

[0051] Typically the primary extraction is carried out at 140-175°C, the secondary extraction at 180-205°C, and optionally extractions at even higher temperatures such as 205-220°C may be carried out.

[0052] Preferably, the aromatized coffee extract contains the coffee aroma fraction and the intermediate coffee extract in a weight ratio of coffee aroma fraction to intermediate coffee extract of 2:5 to 1:20. That is, the stripped aroma fraction is added to the intermediate coffee extract according to these weight ratios. As can be seen, the addition significantly reduces the solids content. For example, adding 2 parts of the coffee aroma fraction (mainly water) to 5 parts of an intermediate coffee extract with a 70% solids content results in an aromatized coffee extract with approximately 50% coffee solids. More preferably, the aromatized coffee extract contains the coffee aroma fraction and the intermediate coffee extract in a weight ratio of coffee aroma fraction to intermediate coffee extract of 1:5 to 1:10.

[0053] More broadly, the coffee aroma fraction re-added to the intermediate coffee extract depends on the fraction of aroma recovered from the roast and ground coffee and the water. For a wider range of aromas recovered (i.e., strip fractions between 1 and 15% by weight), the ratio of coffee aroma fraction to intermediate coffee extract is preferably 1:40 to 30:40. For an intermediate range of aromas recovered (i.e., strip fractions between 5 and 12% by weight), the ratio of coffee aroma fraction to intermediate coffee extract is preferably 5:40 to 24:40. For a strip fraction in the region of about 10% by weight, the ratio of coffee aroma fraction to intermediate coffee extract is preferably 10:40 to 20:40 (i.e., 1:4 to 1:2).

[0054] The coffee aroma fraction is highly desirable for aromatizing coffee extracts because it improves the sensory profile of the product aroma. It has now been found that by providing a homogenization step, a much greater portion of the aroma compounds in the aroma fraction can be maintained during the spray-drying process, resulting in a product with a much improved aroma profile. Furthermore, it has been found that the fine distribution of oil droplets improves the associated mouthfeel and texture of the beverage.

[0055] A preferred method for obtaining an aqueous coffee extract, described in International Application No. PCT / EP2019 / 086859, is now described in more detail. This method utilizes a new extraction process that can fundamentally change the flavor and taste of instant coffee while still relying solely on aqueous extraction. The main condition for bringing about such a change is the use of a much finer grind size combined with lower extraction and hydrolysis temperatures, but without compromising the process yield.

[0056] One advantage of the process is that it can be carried out in a fully continuous manner, which reduces the cost and complexity of the processing equipment. Another advantage is that it can operate with less water, which is of course environmentally desirable, but also leads to significant energy savings when the goal is to obtain a dry powder, since there is less water to remove.

[0057] The process also uses lower than conventional temperatures in the initial heat treatment, which promotes recovery of more desirable coffee flavors. The method ensures that high yields are maintained due to the higher temperature secondary heat treatment.

[0058] Furthermore, the process provides coffee products with improved flavor and taste, particularly beverages with a richer mouthfeel and pleasant flavor notes, surprisingly different from products obtained by conventional methods.

[0059] The method includes a number of steps, many of which will obviously need to be carried out sequentially on a given portion of the material being processed, but it should also be understood that these steps may be carried out as part of a continuous process, batchwise, or a combination of the two.

[0060] In the first step (step (i)), roasted and ground coffee is prepared having an average particle size of 100 to 600 micrometers, preferably 200 to 600 micrometers. The roasted and ground coffee is obtained from roasted and ground coffee beans using techniques well established in the art. The average particle size is D50, measured using a Helos dry laser diffractometer under standard measurement conditions.

[0061] The grind size employed herein is much finer than that used in conventional coffee extraction processes, which typically use a particle size of approximately 2 mm. The fine particle size allows for the formation of a pumpable slurry while increasing the surface area for extraction. Conversely, the energy required to grind coffee to this size is not too great, resulting in undesirable thermal degradation of the beans during grinding.

[0062] Preferably, the roast and ground coffee is ground to an average particle size of 200 to 400 micrometers, more preferably 250 to 350 micrometers, which is in the range of particle sizes traditionally used for producing espresso coffee beverages. This is particularly advantageous because less water needs to be added to create the slurry, as explained below. Furthermore, below 250 micrometers, filtration becomes more difficult and less efficient. Below 100 micrometers, particles may block the filter.

[0063] In another embodiment, the roasted and ground coffee preferably has an average particle size of 400 to 600 micrometers. This is particularly advantageous for producing liquid coffee concentrates. This is because, for liquid products, it is better to use larger particles to reduce the oil content of the product, as oil contributes to the instability of the liquid crema. The larger the particle size, the less oil is released into the resulting extract.

[0064] In a further step (step (ii)), the roast and ground coffee is mixed with water to form a first slurry containing 15-30% by weight of coffee solids. That is, water is added to the coffee beans in a proportion such that the coffee beans provide 15-30% by weight, preferably 20-25% by weight, of the total mixture. The coffee solids include insoluble and soluble coffee solids, some of which dissolve in the added water. This concentration of water provides a pumpable slurry. The amount of water required for a pumpable slurry depends on the size of the grinds used, with coarser grinds requiring more water for pumping. With a grind size of about 250 micrometers, it is readily possible to use dilution to achieve, for example, 25% solids. With a grind size of about 100 micrometers, it is readily possible to use dilution to achieve, for example, 30% solids. However, with a particle size of 400-600 micrometers, it is desirable to add more water to achieve a 15% solids content.

[0065] In a further step (step (iii)), the first slurry is passed through an aroma separation step to recover the coffee aroma fraction and form a de-aromatized slurry. Aroma separation systems are well known in the soluble coffee manufacturing art. An exemplary processing unit is a spinning cone column that can be operated to extract the aroma. This involves the introduction of steam into the slurry to strip the aroma from the coffee, which can be recovered as an aqueous aroma stream that is stored for later use. Step (iii) may be carried out under vacuum.

[0066] The temperature of the slurry in the aroma separation step can be adjusted as needed, but is typically in the range of 70-100°C, e.g., 90-100°C, at the beginning of the treatment. This heat treatment (i.e., aroma separation) is preferably carried out for 10 seconds to 2 hours, 1 minute to 25 minutes, preferably 1 to 5 minutes. In an alternative embodiment, the duration may be 15 to 25 minutes. Of course, if aroma recovery techniques are used, the temperature may be affected by the addition of steam. Aroma separation can be carried out under vacuum.

[0067] The temperature of the slurry can be increased prior to the aroma separation step by heating water added either before or after the slurry is formed. The temperature change can be achieved using heat recovered from other steps in the process, for example, by using a conventional heat exchanger. Preferably, the water in step (ii) is at a temperature of 80-100°C when mixed with the coffee. This is because it is cheaper to add hot water than to heat it together with the beans or to heat the slurry using steam. If the water is not heated before mixing with the coffee, it is added at a temperature of 15-40°C, and the subsequent slurry is heated to 80-100°C. This option has the advantage of improved process simplification.

[0068] At this point in the process after step (iii), the slurry comprises soluble coffee solids, dealomatized insoluble coffee solids, and water.

[0069] In a further step (step (A)), the dearomatized slurry is passed through a first filter at a temperature of 90 to 150°C, preferably 90 to 120°C, and more preferably 90 to 100°C, to form a first coffee extract and a first filter cake. In a preferred embodiment, the dearomatized slurry is passed through the first filter at a temperature of 140 to 150°C. This process thus separates the majority of the soluble coffee solids and water from the insoluble coffee solids. The first filter can be one of several known filtration systems, including settlers, filters, and centrifuges. Filters are preferred because of their efficient continuous processing and versatility in handling fine particles. Most preferably, a continuous filter is used. This allows for efficient separation of the insoluble solids from the water, resulting in a recovery of soluble solids of greater than 90%.

[0070] The coffee solids in the filter cake may be washed or pressed to increase the extraction of the soluble coffee solids. The concentrated coffee liquor, the first coffee extract, may be saved for later use in the process or added directly to a later step in a continuous version of the process.

[0071] In a further step (step (B)), water is added to the first filter cake to form a reconstituted slurry having at least 12% by weight of coffee solids. That is, water is added in an amount necessary to produce a slurry having a slightly lower solids concentration than that of the first slurry formation step. Preferably, the reconstituted slurry formed in step (e) has a solids content of 12-30% by weight, more preferably 12-20% by weight. This solids concentration is selected to achieve the desired pumpability. Reconstitution can also be carried out with heated water, if necessary.

[0072] Preferably, the water in step (B) is at a temperature of 80-100°C, as adding hot water is inexpensive and also helps achieve some of the temperatures required in the following steps. Heat may be recovered from other steps in the process.

[0073] In a further step (step (C)), the reconstituted slurry is heat-treated at a temperature of 150-205°C, preferably 170-205°C, more preferably 180-205°C. This heating is preferably carried out at elevated pressure to improve the extraction rate. A preferred pressure is 2-30 bar, e.g., 15 bar. This heat treatment is preferably carried out for 5 minutes to 2 hours, preferably 5-15 minutes, preferably 5-10 minutes. In an alternative embodiment, the duration may be 15-25 minutes. During this step, a portion of the insoluble coffee solids may be hydrolyzed to soluble solids, which may then be recovered. This step may be carried out using a plug flow reactor.

[0074] At this point in the process, the slurry again contains soluble coffee solids, insoluble coffee solids, and water, and can be subjected to a flashing process in which a reduction in pressure allows for the removal of any undesirable aroma flavors.

[0075] In a further step (step (D)), the heat-treated reconstituted slurry is passed through a second filter to form a second coffee extract and a second filter cake. The filter may be any filter as described above, which serves to separate the coffee liquor containing dissolved soluble coffee solids from the insoluble coffee solids. The second filter cake may be washed and / or pressed again to recover additional coffee extract. The second coffee extract generally has a lower soluble solids concentration than the first coffee extract.

[0076] The concentrated coffee liquor, the second coffee extract, may be stored for later use in the process.

[0077] In a further step (step (E)), the first and second coffee extracts are combined to form a third coffee extract. The two coffee extracts are generally combined to provide the third by simple mixing.

[0078] In a further step (step (F)), the third coffee extract is concentrated to form a fourth coffee extract having a coffee solids content of 35-70% by weight, preferably 35-65% by weight, and more preferably 40-50%. When aroma is added in step (v) below, the solids concentration after step (F) is preferably 55-60% to allow for dilution to a useful final concentration. This serves to provide a coffee extract suitable for use as a concentrate (i.e., flowable) or for use in a drying process to produce a dried product (i.e., with less water to remove). Preferably, step (F) is carried out in an evaporator unit.

[0079] In a further step (step (v)), the coffee aroma fraction (from step (iii)) is added to the fourth coffee extract (also referred to herein as the intermediate coffee extract) to form an aromatized coffee extract, which is then homogenized and spray-dried in steps (b) and (c). This improves the flavor of the extract without compromising the solids concentration. Adding back the aroma after the concentration step prevents a limited amount of aroma from being lost from the product. The resulting coffee extract preferably has a coffee solids content of 35-65% by weight, preferably 45-65% by weight.

[0080] The coffee extract product is a soluble powder. That is, the method further comprises step (c) of spray-drying the aromatized coffee extract to form a soluble powder. Preferably, the powder product has an average particle size of 200 to 3000 micrometers, more preferably 500 to 2000 micrometers. The product can be agglomerated to the desired particle size in a spray dryer or fluidized bed, or by any other known technique.

[0081] The coffee solids remaining after step (D) may be treated as a waste stream or incinerated to provide energy for the process (e.g., to heat water). Alternatively, the second filter cake may be subjected to a further high-temperature extraction process to obtain a further coffee extract, which is then mixed with the first and second coffee extracts in step (E) to form a third coffee extract. Suitable conditions for this further high-temperature processing step are temperatures of 190 to 215°C. This heat treatment is preferably carried out for 5 minutes to 2 hours, preferably 15 to 25 minutes. This further step can be carried out using a further set of slurry formation and filtration steps, or using conventional extraction techniques.

[0082] Generally, the method uses less water than conventional extraction methods. The use of high solids concentrations reduces the energy consumption for the associated concentration step. The process also allows for efficient recycling of heat between different stages by adding heated water at different stages and heat recoverable from the product of the hot extraction step.

[0083] Preferably, the method further comprises packaging the coffee extract product.

[0084] Preferably, the method further comprises an agglomeration step to improve solubility and increase the particle size of the final product, thereby avoiding problems associated with dust and fines.

[0085] According to a further aspect, there is provided a coffee extract product obtainable by the methods described herein.

[0086] The finished instant coffee product exhibits improved flavor with less process flavor and an improved flavor closer to freshly brewed coffee. Undesirable process acidity produced by processing at higher temperatures is also reduced.

[0087] According to a further aspect there is provided a spray-dried coffee powder for forming a coffee beverage, comprising: the powder comprises particles including soluble coffee solids and insoluble coffee solids, the insoluble coffee solids including coffee oil and an insoluble coffee sediment fraction that is the non-oily portion of the insoluble coffee solids; the powder comprises at least 6% by weight of an insoluble coffee sediment fraction, the insoluble coffee sediment fraction comprising no more than 1% by weight of arabinose as analyzed after acid hydrolysis; The powder contains at least 0.8% by weight of coffee oil on a dry basis; and The particles exhibit less than 20% by weight of surface coffee oil based on the total weight of coffee oil.

[0088] According to a further aspect there is provided a spray-dried coffee powder for forming a coffee beverage, comprising: the powder comprises particles including soluble coffee solids and insoluble coffee solids, the insoluble coffee solids including coffee oil and an insoluble coffee sediment fraction that is the non-oily portion of the insoluble coffee solids; the powder comprises at least 6% by weight of an insoluble coffee sediment fraction, the insoluble coffee sediment fraction comprising no more than 1% by weight of arabinose as analyzed after acid hydrolysis; The powder contains at least 0.8% by weight of coffee oil on a dry basis; and The powder, when reconstituted in water, provides a particle size distribution of oil droplets having a D50 oil droplet size of less than 8 micrometers, less than 7 micrometers, more preferably less than 5 micrometers, and most preferably less than 4 micrometers, for example, 1 to 7 micrometers, most preferably 1 to 5 micrometers, more preferably 2 to 4 micrometers, and more preferably 2.5 to 3.5 micrometers.

[0089] According to a further aspect there is provided a spray-dried coffee powder for forming a coffee beverage, comprising: the powder comprises particles including soluble coffee solids and insoluble coffee solids, the insoluble coffee solids including coffee oil and an insoluble coffee sediment fraction that is the non-oily portion of the insoluble coffee solids; the powder comprises at least 6% by weight of an insoluble coffee sediment fraction, the insoluble coffee sediment fraction comprising no more than 1% by weight of arabinose as analyzed after acid hydrolysis; The powder contains at least 0.8% by weight of coffee oil on a dry basis; and The powder can be obtained by spray-drying an aromatized aqueous coffee extract. The aromatized aqueous coffee extract refers to an aqueous coffee extract containing a coffee aroma fraction and a coffee extract, the coffee aroma fraction being obtained by stripping 5 to 12% by weight, preferably about 10% by weight, of fresh roasted and ground coffee beans, and the aromatized coffee extract contains the coffee aroma fraction and the coffee extract in a weight ratio of coffee aroma fraction to coffee extract of 2:5 to 1:20. Fresh means that the extract has not been previously extracted.

[0090] The following discussion of preferred features applies to all aspects of the invention relating to spray-dried coffee powder, and furthermore, all of these aspects may be freely combined with other aspects described herein.

[0091] The inventors have found that the above process results in a unique spray-dried coffee powder. In particular, the product has an improved aroma and mouthfeel compared to conventional commercial coffee products. The presence of a high oil content and subsequent homogenization has been found to result in an improved mouthfeel and also to better retain the aroma compounds added back into the coffee during the aroma re-addition step. This results in a new and improved soluble coffee product that rivals the performance of premium freeze-dried coffee.

[0092] The product is characterized, in part, by (i) comprising at least 6% by weight of an insoluble coffee sediment fraction, the insoluble coffee sediment fraction containing 1% by weight or less of arabinose, as analyzed after acid hydrolysis, and (ii) comprising at least 0.8% by weight of coffee oil on a dry basis. These characteristics are characteristic of the slurry extraction process described herein. In particular, the very fine grind size of the extracted coffee results in a higher oil yield. Furthermore, the fine size and slurrying step lead to the incorporation of a sediment fraction having a characteristic arabinose level indicative of partial extraction of insoluble material during coffee processing. Thus, a soluble coffee product is essentially produced by the described method.

[0093] Furthermore, as a result of the stable oil-in-water emulsion obtained by the homogenization process, there is less oil on the surface. Thus, the product has characteristics unique to the product from which it is obtained that are not observed with other processing methods. Preferably, the product of the further aspect is obtainable by the method described herein.

[0094] When combined with the method of International Application No. PCT / EP2019 / 086859, as discussed herein, the present process results in an insoluble coffee sediment fraction and higher levels of oil in the product as a direct result of the process, without the need for separate oil or roast and ground coffee additions. Thus, the present process is an elegant approach to providing an improved product from roast and ground coffee at high yields.

[0095] The insoluble coffee fraction is superficially similar to roasted and ground coffee additives that are often added to coffee products to improve the aroma of conventional coffee extracts. However, the insoluble coffee sediment fraction is present in the product as a direct result of the process and does not require the additional step of adding roasted and ground coffee to the coffee extract. Thus, the products of the present invention can be characterized by the presence of the insoluble coffee sediment fraction, which distinguishes them from commercially available coffee products to which additional roasted and ground coffee has not been added.

[0096] Surprisingly, the inventors have found that the insoluble coffee sediment fraction obtained as a direct result of the process is less likely to settle out of the extract than the roast and ground coffee extract after addition, as observed in the final beverage, which has significantly less sediment or scum deposited on the walls of the container after the beverage is stirred in the container.

[0097] The insoluble coffee sediment fraction obtained by the above process further differs from the insoluble coffee sediment fraction observed for coffees supplemented with conventional roast and ground coffee additives because the fraction undergoes the coffee extraction process, exposing it to a heated aqueous environment that alters the carbohydrate balance in the insoluble coffee material. Thus, the products of the present invention can be characterized by a carbohydrate analysis of the insoluble coffee sediment fraction that distinguishes them from commercially available coffee products supplemented with additional roast and ground coffee.

[0098] Additionally, the present process results in a higher oil fraction in the coffee product. This is a result of the finer coffee particle grind size used in the present method. It is understood that finer grinds expose more surface area of ​​the coffee for extraction, resulting in greater amounts of oil being released during the extraction process. Thus, the products of the present invention can be characterized by the presence of a higher oil fraction, which distinguishes them from commercially available coffee products obtained by conventional extraction processes.

[0099] The insoluble coffee sediment fraction is the sediment obtained using the repeated centrifugation process described herein. It represents the solid material (not oil) present in the product that is insoluble in water.

[0100] The composition preferably comprises 7.5 to 15% by weight of the insoluble coffee sediment fraction, which provides a balanced aroma without having an excessively high amount of insoluble material which may adversely affect mouthfeel or cause undesirable sediment.

[0101] Preferably, the insoluble coffee sediment fraction contains 0.5 to 1% by weight of arabinose when analyzed after acid hydrolysis.

[0102] Preferably, the insoluble coffee sediment fraction contains less than 5% by weight of galactose, preferably 2-4% by weight of galactose, when analyzed after acid hydrolysis.

[0103] Preferably, the instant coffee composition comprises at least 1% by weight of coffee oil, preferably 1.5-5% by weight, preferably 2-4% by weight, of coffee oil by dry weight. Increasing the oil concentration improves the mouthfeel of the product. Higher levels of oil improve mouthfeel and also increase the yield by weight obtained and used from the coffee beans. The oil obtained as a result of the process has been found to be well distributed within the extract, helping to improve mouthfeel without an undesirable oily film visible on the final beverage.

[0104] Preferably, the particles exhibit less than 20% by weight of surface coffee oil, based on the total weight of coffee oil. Surface oil can be measured by solvent extraction techniques. Exemplary solvent extraction techniques are discussed in the Examples below. Preferably, the particles exhibit less than 15% by weight, and preferably less than 10% by weight, of surface coffee oil, based on the total weight of coffee oil. Without being bound by theory, it is believed that this low level of surface oil is a direct result of the homogenization process described herein. In particular, by obtaining a finer, more well-dispersed oil-in-water emulsion throughout the extract prior to spray drying, the emulsion is less disrupted by the spray drying process. Thus, the oil remains well-distributed throughout the particle, rather than agglomerating at the surface. This is believed to contribute to improved product performance, as the fine oil structure can be maintained upon reconstitution in a beverage medium (i.e., hot water at 80-95°C).

[0105] In particular, the particles preferably exhibit less than 20 wt.% surface coffee oil based on the total weight of coffee oil, such as less than 19 wt.%, for example less than 18 wt.%, such as less than 17 wt.%, for example less than 16 wt.%, such as less than 15 wt.%, for example less than 14 wt.%, such as less than 13 wt.%, for example less than 12 wt.%, such as less than 11 wt.%, for example less than 10 wt.%, such as less than 9 wt.%, for example less than 8 wt.%, such as less than 7 wt.%, for example less than 6 wt.%, such as less than 5 wt.%, for example less than 4 wt.%, such as less than 3 wt.%, for example less than 2 wt.%, such as less than 1 wt.% surface coffee oil based on the total weight of coffee oil.

[0106] Preferably, the spray-dried coffee particles, when reconstituted in water, produce an oil droplet size distribution with a D50 of less than 8 micrometers, less than 7 micrometers, more preferably less than 5 micrometers, and most preferably less than 4 micrometers, e.g., 1-7 micrometers, most preferably 1-5 micrometers, more preferably 2-4 micrometers, and more preferably 2.5-3.5 micrometers. This particle size can be determined using confocal laser scanning microscopy, for example, using a Zeiss Z2M instrument. Samples can be fluorescently labeled and imaged using confocal laser scanning microscopy (CLSM) with the lipid dye BODIPY™ to localize the oil droplets within the emulsion. Imaging can be performed using a 488 nm laser and a 490-555 nm bandpass filter to pseudocolor the fat regions green. Particle size results can be successfully measured using image analysis, which ignores non-spherical or brown coffee particles. A representative sample of at least 1,000 oil droplets should be measured. Samples are observed at a standard beverage concentration of approximately 1.5% solids by weight.

[0107] Preferably, when dissolved at a concentration of 1.5% by weight (solids) and analyzed by wet laser diffraction, the instant coffee composition has a unimodal particle size distribution. This distinguishes it from products in which roast and ground coffee is added as an additive to soluble coffee powder (generally in a coffee extract before drying). Specifically, conventional milling techniques for crushing coffee beans generally produce a bimodal distribution based on the crushing of the coffee beans, with a lower peak resulting from the finest cell wall fragments. In contrast, coffee particles retained after the method of the present invention, or in a conventional extract effluent from a percolation column, have a bimodal distribution.

[0108] Preferably, under the same particle measurement conditions, the instant coffee composition also has a D50 of less than 10 micrometers, preferably 2.5 to 7.5 micrometers, when dissolved. This fine particle size reflects the impact on the extract obtained from the coffee process described above. Indeed, the observed particle size distribution is unusual, as the D90 is typically greater than 30 micrometers, reflecting a broad particle size distribution.

[0109] Preferably, the composition consists of coffee, i.e., the coffee composition does not include any non-coffee ingredients or additives (such as emulsifiers or dairy ingredients). However, it will be appreciated that the spray-dried coffee powder may be mixed with other non-coffee ingredients, such as sugar or milk powder, to provide a final combination product, such as a three-in-one mix.

[0110] Quantification and analysis of the insoluble coffee sediment fraction requires separation of the insoluble coffee solids from the soluble coffee solids. To facilitate this evaluation of liquid coffee products, the product must be dried to a powder so that the same analysis can be performed.

[0111] To isolate and quantify the insoluble coffee sediment fraction (also known as sediment), 30 grams of a given coffee sample (dry powder) is added to 70 grams of boiling water and shaken for 2 minutes. The sample is then centrifuged at 10,000 g for 15 minutes. After centrifugation, the supernatant is decanted, and the sediment is redissolved in 70 grams of boiling water, shaken for 2 minutes, and then centrifuged again under the same conditions as above. This washing process is repeated three times for a total of four centrifugation steps. The sediment from the final wash is then freeze-dried, with the percentage of sediment relative to the 30 g starting sample (e.g., 1.8 g of sediment represents 6% by weight of the insoluble coffee sediment fraction). Before any analysis is performed, the dried sediment sample is homogenized by simple stirring.

[0112] Considering the method of analyzing the insoluble coffee sediment fraction, the fraction, even though considered insoluble, does not contain any coffee oil that may be present, as the oil is easily separated in the centrifugation step.

[0113] To test for carbohydrates within the isolated insoluble coffee sediment fraction, total carbohydrate analysis is performed using high-performance anion exchange-pulsed amperometric detection (HPAEC-PAD) in accordance with ISO 11292-1995. Samples are prepared by mixing the previously isolated sediment with 50 ml of 1 M HCl and then shaking the sample at 95°C for 150 minutes. Monosaccharide quantification is performed by analyzing external standards of common monosaccharides.

[0114] To determine the particle size distribution of instant coffee products, particle size distribution analysis was performed using a Malvern Mastersizer 3000 with a Hydro MV tank. A 1.5 g sample (±0.0005 g) was made up to 100 g (±0.05 g) with boiling deionized water at 100°C, stirred for 60 seconds, cooled slightly, and dropped into the Malvern unit to achieve approximately 10% opacity. An average of three readings was taken. Again, to facilitate evaluation of this liquid coffee product, it is necessary to dry the product to a powder so that the same analysis can be performed.

[0115] To determine the oil content, a sample of the product (first dried if the product was a liquid coffee concentrate) was evaluated using a Soxtec H6. A 2g sample was mixed with 40-60g of petroleum ether, boiled for 2 hours, and then rinsed for approximately 0.5 hours. The resulting condensate was then heated to recover the solvent. The evaluation of oil concentration in this manner is well known in the art.

[0116] In some embodiments, the instant coffee compositions of the present invention may be blended with conventional spray-dried coffee obtained by known methods. For example, the product may contain 10-100%, e.g., 20-50%, of the coffee described herein blended with the remainder of the conventional coffee. While this is easily achievable for liquid products, soluble products may be formed from mixed liquid extracts or by dry blending different powdered products. This may be advantageous in that the mouthfeel and palatability of the present invention may be toned down to provide a more traditional beverage experience.

[0117] According to a preferred embodiment there is provided a method for producing coffee powder, the method comprising the steps of: (a) providing roasted and ground coffee having an average particle size of 100 to 600 micrometers; (b) mixing roast and ground coffee with water to form a first slurry containing 15-30% by weight coffee solids; (c) passing the first slurry through an aroma separation step to recover a coffee aroma fraction and form a de-aromatized slurry; (d) passing the dearomatized slurry through a first filtration device at a temperature of 90-150°C to form a first coffee extract and a first filter cake; (e) adding water to the first filter cake to form a reconstituted slurry having at least 12% by weight coffee solids; (f) heat treating the reconstituted slurry at a temperature of 150-205°C; (g) then passing the heat-treated reconstituted slurry through a second filtration device to form a second coffee extract and a second filter cake; (h) combining the first and second coffee extracts to form a third coffee extract; (i) concentrating the third coffee extract to form a fourth coffee extract having 35 to 70% by weight coffee solids; (j) adding the coffee aroma fraction to a fourth coffee extract to form an aqueous coffee extract comprising 30-55% by weight of soluble coffee solids and 1-10% by weight of oil, preferably 2-5% by weight of oil, wherein the aqueous coffee extract consists of water and coffee-derived components; (k) subjecting the aqueous coffee extract to a two-stage homogenization process to obtain a homogenous coffee extract, the first stage being carried out at 200-1000 bar and the second stage being carried out at 10-100 bar; (l) spray drying the homogeneous coffee extract to form a coffee powder.

[0118] According to a preferred embodiment there is provided a method for producing coffee powder, the method comprising the steps of: (a) providing roasted and ground coffee having an average particle size of 100 to 600 micrometers; (b) mixing roast and ground coffee with water to form a first slurry containing 15-30% by weight coffee solids; (c) passing the first slurry through an aroma separation step to recover a coffee aroma fraction and form a de-aromatized slurry, wherein the aroma separation step recovers 1 to 15% by weight of the coffee composition as the coffee aroma fraction, preferably 8 to 12% by weight of the coffee composition as the coffee aroma fraction, and most preferably about 10% by weight of the coffee composition; (d) passing the dearomatized slurry through a first filtration device at a temperature of 90-150°C to form a first coffee extract and a first filter cake; (e) adding water to the first filter cake to form a reconstituted slurry having at least 12% by weight coffee solids; (f) heat treating the reconstituted slurry at a temperature of 150-205°C; (g) then passing the heat-treated reconstituted slurry through a second filtration device to form a second coffee extract and a second filter cake; (h) combining the first and second coffee extracts to form a third coffee extract; (i) concentrating the third coffee extract to form a fourth coffee extract having 35 to 70% by weight coffee solids; (j) adding a coffee aroma fraction to the fourth coffee extract to form an aqueous coffee extract comprising 30-55% by weight of soluble coffee solids and 1-10% by weight of oil, preferably 2-5% by weight of oil, wherein the aqueous coffee extract consists of water and coffee-derived components, and the aromatized coffee extract contains the coffee aroma fraction and an intermediate coffee extract in a weight ratio of coffee aroma fraction to intermediate coffee extract of 2:5 to 1:20, preferably 1:10 to 3:10, and most preferably about 1:5; (k) subjecting the aqueous coffee extract to a two-stage homogenization process to obtain a homogenous coffee extract, the first stage being carried out at 200-1000 bar and the second stage being carried out at 10-100 bar; (l) spray drying the homogeneous coffee extract to form a coffee powder.

[0119] These preferred embodiments can be freely combined with all further features of the first aspect. The present invention will now be further explained in conjunction with the drawings. [Brief explanation of the drawings]

[0120] [Figure 1] 1 shows a flow chart of the process of the present invention. [Example]

[0121] As shown in Figure 1, the process for producing a coffee extract product involves a number of steps.

[0122] Step (a) provides roast and ground coffee 2 having an average particle size of 100 to 600 micrometers, preferably 200 to 600 micrometers. Within this range, larger sizes are advantageous for liquid extract products, while smaller sizes are advantageous for dry soluble coffee products.

[0123] In step (b), the roast and ground coffee is mixed with water 5 to form a first slurry 10 containing 15-30% by weight coffee solids. The water 5 is added at a temperature of 80-100°C, preferably 90-95°C. The solids concentration is determined by particle size, with a minimum amount of water 5 being used if necessary to obtain a pumpable slurry 10. The larger the particle size, the more water 5 is required (the lower the solids content) to obtain a pumpable slurry 10.

[0124] In step (c), the first slurry 10 is passed through an aroma separation process to recover a coffee aroma fraction 15 and form a de-aromatized slurry 20. A typical approach to this process involves adding steam 21 to the pumpable slurry 10, which is treated in a spinning cone treatment unit. The recovered aroma fraction 15 is about 10% by weight of the first slurry 10, such that the de-aromatized slurry 20 is 90% by weight of the slurry 10.

[0125] In step (d), the dearomatized slurry 20 is passed through a first filtration device at a temperature of 90-150°C, for example 90-100°C, to form a first coffee extract 25 and a first filter cake 30. The temperature can be maintained from the previous step or can be further increased to increase the extraction yield. The filter cake 30 is washed and pressed to obtain the maximum possible amount of soluble coffee solids.

[0126] In step (e), water 5 is added to the first filter cake 30 to form a reconstituted slurry 35 having at least 12% by weight coffee solids. The water 5 is preferably at an elevated temperature and there may be mechanical agitation to break down the first filter cake 30. The amount of water required to reconstitute the slurry tends to be greater than the amount required in step (b).

[0127] In step (f), the reconstituted slurry 35 is heat-treated at a temperature of 150-205°C, e.g., 180-205°C, to form a heat-treated reconstituted slurry 40, i.e., pumped through a heat-treatment unit, such as a plug flow reactor. The residence time in the heat treatment is typically at least 5 minutes to ensure good extraction.

[0128] In step (g), the heat-treated reconstituted slurry 40 is passed through a second filtration device to form a second coffee extract 45 and a second filter cake 50. The second filter cake 50 is washed and pressed to obtain the maximum possible amount of soluble coffee solids. The temperature in this step may be maintained from the previous step or may be reduced to a temperature of, for example, 80-100°C when heat is recovered for use in step (b).

[0129] The second filter cake 50 may then be combusted in step M to generate heat for the process or may be subjected to a further high temperature extraction step M to obtain a further coffee extract 52.

[0130] In step (h), the first coffee extract 25 and the second coffee extract 45 are combined to form a third coffee extract 55. Other aqueous coffee extracts may also be added in this step (e.g., further coffee extract 52).

[0131] In step (i), the third coffee extract 55 is concentrated to form a fourth coffee extract 60 having a coffee solids content of 35-70% by weight, such as 35-60% by weight coffee solids.

[0132] In step (j), the coffee aroma fraction 15 is added to the fourth coffee extract 60 (the intermediate coffee extract) to form an aromatized coffee extract 65. The aroma fraction 15 is added in an amount of 1 part to 5 parts of the fourth coffee extract 60.

[0133] The aromatized coffee extract 65 is homogenized in step k in a two-stage homogenizer 70 to form a homogenous coffee extract 75. The two-stage homogenizer 70 operates at a pressure of 700 bar for the first stage and 50 bar for the second stage.

[0134] The homogenous coffee extract 75 is spray dried in step (L) to form a dried coffee product 80.

[0135] The invention will now be further described in connection with the following non-limiting examples.

[0136] Example 1 The roasted whole beans were crushed to 200 μm to 400 μm using a three-stage roller crusher.

[0137] Roasted and ground coffee was slurried at 20°C to 30°C in a ratio of 25% coffee to 75% water.

[0138] The slurry was fed into a heat exchanger and heated to 95°C before being transferred to a spinning cone column where the aromas were stripped from the slurry.

[0139] Upon exiting the spinning cone, the slurry was fed into a heat exchanger where the temperature was raised to 120°C-150°C for 2-5 minutes.

[0140] The slurry was then fed into a filter which separated the coffee liquor from the grounds, which were then subjected to two further washing steps at 130°C to 150°C to remove additional solids.

[0141] The ground material was then reslurried in fresh water at a solids ratio of 12% to 17%. The resulting slurry was fed to a hydrolysis step heated to 180°C to 205°C (185°C) and held for 5 to 20 minutes.

[0142] The resulting slurry was then cooled to below 100°C before being passed through a second filtration step which repeated the separation and washing of the first separation step.

[0143] The coffee extracts from each filtration step were combined and concentrated. The aroma compounds stripped from the first slurry were then added to the mixture.

[0144] The three thoroughly combined components were then subjected to homogenization at 200 bar and then at 40 bar. The homogenized extract was spray dried in a conventional manner to obtain a soluble coffee powder.

[0145] Example 2 Arabica and / or Robusta beans were roasted and ground to an average particle size of 300 μm using a three-stage roller grinder. The ground coffee was then slurried with water at 20-25°C in a ratio of 25% coffee to 75% water.

[0146] The slurry was fed into a heat exchanger and heated to 70°C, then transferred to a spinning cone column to strip the aromas from the slurry.

[0147] The slurry was then fed to a filter at a temperature of 95°C to separate the coffee liquor from the grounds, which were then subjected to two further washing steps to remove additional solids.

[0148] The ground material was then reslurried in fresh water at a solids ratio of 12% to 17%. The resulting slurry was fed into a plug flow reactor heated to 170°C (hydrolysis step) and held for 5 to 10 minutes.

[0149] The resulting slurry was then cooled to below 100°C before being passed through a second filtration step which repeated the separation and washing of the first separation step.

[0150] The coffee extracts from each filtration step were combined and concentrated. The aroma compounds stripped from the first slurry were then added to the mixture.

[0151] The three thoroughly combined components were then subjected to homogenization at 200 bar and then at 40 bar. The homogenized extract was spray dried in a conventional manner to obtain a soluble coffee powder.

[0152] The product of this example was found to have more body / mouthfeel than products made using current technology.

[0153] Example 3 A coffee slurry was prepared as described in Example 1.

[0154] The slurry was fed into a heat exchanger and heated to 95°C, then transferred to a spinning cone column to strip the aromas from the slurry.

[0155] Upon exiting the spinning cone, the slurry was fed into a heat exchanger where the temperature was raised to 145-150°C for 4-5 minutes.

[0156] The slurry was then fed to a filter which separated the coffee liquor from the grounds, which were then subjected to two further washing steps at 140°C to remove additional solids.

[0157] The slurry was then fed into a filter which separated the coffee liquor from the grounds.

[0158] The ground material was then reslurried in fresh water at a solids ratio of 12% to 17%. The resulting slurry was fed into a plug flow reactor heated to 200°C (hydrolysis step) and held for 7 to 10 minutes.

[0159] The resulting slurry was then cooled to below 100°C before being passed through a second filtration step which repeated the separation and washing of the first separation step.

[0160] The coffee extracts from each filtration step were combined and concentrated. The aroma compounds stripped from the first slurry were then added to the mixture.

[0161] The three thoroughly combined components were then subjected to homogenization at 200 bar and then at 40 bar. The homogenized extract was spray dried in a conventional manner to obtain a soluble coffee powder.

[0162] The product of this example was found to have more body / mouthfeel than products made using current technology.

[0163] Example 4 Arabica and / or Robusta beans were roasted and ground to an average particle size of 400 μm using a three-stage roller grinder. The ground coffee was then slurried with water at 20-25°C in a ratio of 15% coffee to 85% water.

[0164] The rest of the process was carried out as in Example 1.

[0165] The resulting product has a lower concentration of oil than the product of Example 1.

[0166] Oil droplet evaluation The size of the oil droplets in coffee extracts produced according to method P1 (see Example 1) was studied before and after homogenization at various stage 1 pressures. Stage 2 was 40 bar in each case. The time indicates the stability after homogenization.

[0167] As shown in the data, higher pressures give greater oil droplet stability over time. Higher pressures also give smaller D50 sizes and a narrower distribution range (D90-D10).

[0168] The concentration of the extract also affects size and stability: the weak concentrate was only 10% solids by weight, whereas the concentrated extract was 50% solids by weight.

[0169] This demonstrates that the D50 value for the non-homogenized high oil extract is about 9.6 micrometers, while the homogenized high oil extracts have much lower D50s of about 3.2 and 2.9. Note that the data for the weak extracts, which are outside the claimed solids range and have too much water for spray drying, still support the same trend.

[0170] [Table 1]

[0171] Further Examples The following examples were carried out using the methods of International Application No. PCT / EP2019 / 086859 (hereinafter P1) and are provided as evidence of at least the comparative properties of prior art compositions.

[0172] Samples obtained by the methods described herein were evaluated against a range of commercially available soluble coffee products. Comprehensive testing shows that the products obtained by the process are novel and readily distinguishable from products obtained from conventional processes.

[0173] [Table 2] * Competitive bean information is based on educated guesses

[0174] Examples 7, 8, 9, and 10 were produced according to the method described in P1. Examples 1 to 6 are commercially available products, of which 2 and 4 are products containing roasted and ground coffee additives (labeled "whole bean instant" in the table).

[0175] It should be understood that the concentration of oil in Robusta beans is generally lower than that in Arabica beans, which is reflected in the generally lower oil concentration of products containing Robusta beans, including inventive Example 9. Sample 10 is Dark Brazil, known for its high oil concentration.

[0176] As can be seen, low concentrations of oil are present in pure instant coffee, i.e., samples 1, 3, 5, and 6, which do not contain the roasted and ground coffee additive. The oil concentration is slightly higher in samples 2 and 4 due to the oil content of the roasted and ground coffee additive, with sample 2 containing approximately 5% roasted and ground coffee and sample 4 containing more roasted and ground coffee.

[0177] Samples 7, 8, and 10 contain high concentrations of oil because they are finely ground roasted coffee in a process that releases more oil into the extract.

[0178] As can be seen, conventional soluble coffee products do not contain significant levels of oil, and in fact it is speculated that the levels of oil observed in some of these products are later added to the surface of the dry powder to improve its aroma.

[0179] The only prior art products containing high oil concentrations are the result of adding roasted and ground coffee additives to the product. In contrast, the method described in P1 achieves high oil concentrations, even in Robusta bean products.

[0180] Sediment concentration Sediment concentration was determined by adding 30 grams of a given coffee sample to 70 grams of boiling water and shaking for 2 minutes. The sample was then centrifuged at 10,000 g for 15 minutes. After centrifugation, the supernatant was decanted and the sediment was redissolved in 70 grams of boiling water, shaken for 2 minutes, and then centrifuged again under the same conditions as above. This washing process was repeated three times for a total of four centrifugation steps. The sediment from the final wash was then freeze-dried, where the percentage of sediment is relative to the 30 g starting sample (e.g., 1.8 g of sediment represents 6% by weight of the insoluble coffee sediment fraction).

[0181] [Table 3]

[0182] Examples 7, 8, and 9 were prepared according to the method described in P1. Examples 1-6 are commercial products, of which 4, 5, and 6 are products supplemented with roast and ground coffee additives.

[0183] As can be seen, all commercially available instant coffee products have some insoluble coffee sediment fraction, which is expected to be small fragments of coffee cell walls that pass through the extraction system into the coffee extract. The concentration of the insoluble coffee sediment fraction typically increases for products supplemented with roast and ground coffee additives.

[0184] As can be seen, all of the products made according to the method described in P1 have significantly higher concentrations of insoluble coffee sediment fraction than instant coffee products not supplemented with roast and ground coffee additives.

[0185] [Table 4]

[0186] Examples 7, 8, and 9 were prepared according to the method described in P1. Examples 1-6 are commercial products, of which 4, 5, and 6 are products supplemented with roast and ground coffee additives.

[0187] Sedimentation assays involving multiple centrifugation steps allow for the recovery of large amounts of very fine particles.

[0188] Particle size distribution was measured on a Malvern 3000 after making a 1.5% hot brew of the dry product, for example 3g of dry product in 200ml hot water.

[0189] Three classes of sediments can be distinguished: Class 1 L'Or Intense™, Kenco Rich™, and Carte Noir™: Unimodal distribution D10: less than 1.5 and D90: less than 15 μm Relatively small amount of sediment, less than 5.5% by weight The very small particle size (e.g., low D90) likely reflects the flow of these particles from the extraction column into the extract or mannan settling in the evaporator.

[0190] Class 2: Kenco Milicano™, Nescafe Gold™, and Azera™ are clearly different from Classes 1 and 3. Bimodal distribution (two peaks): Peak 1 between 1 and 10 μm and Peak 2 between 10 and 100 μm.

[0191] Class 3: Samples of the present invention Unimodal distribution, but broader than class 1, D10: greater than 1.0 and D90: greater than 15 μm, and relatively large amounts of sediment, such as greater than 7.5 wt %.

[0192] Carbohydrate Analysis This analysis is of monosaccharides after acid hydrolysis.

[0193] [Table 5]

[0194] Examples 7, 8, and 9 were prepared according to the method described in P1. Examples 1-6 are commercial products, of which 4, 5, and 6 are products complemented with roasted and ground coffee additives.

[0195] As can be seen, the insoluble coffee sediment fraction of the P1 product has a concentration of arabinose roughly equivalent to that of a soluble coffee product without added roast and ground coffee. Typically, it also has a lower concentration of galactose than a soluble coffee product with added roast and ground coffee.

[0196] Without being bound by theory, it is believed that the high concentration of arabinose in the complementary product is the result of the presence of unextracted coffee material. In contrast, in the P1 product, the concentration is lower, reflecting the fact that arabinose has already been extracted into the soluble coffee fraction by the P1 process.

[0197] Sensory testing Two prototypes of P1's product were paired with a current technology product in a ratio of 30 (POI):70 (current product). These were then tested in sets with an additional sample of 100% current technology product. Three samples were given to a panel of sensory experts, who were then asked to pair the products according to similarities / differences with the third one.

[0198] The results show that even at only 30% concentration in a blend with the current product, the prototype appears more viscous / drier and powdery, all attributes that contribute to mouthfeel / body. Concentration directly correlates with tribology data. More oil means more lubrication, which means better mouthfeel / body. The effect is shown in Figure 3.

[0199] Collapse temperature Crystalline products have a well-defined "eutectic" freezing / melting point, called their collapse temperature. When freeze-drying concentrated coffee extracts, the extract is heated under vacuum from an initial freezing temperature of approximately -50°C, allowing the water to sublimate. The heating rate is extract-dependent, and there is a collapse temperature above which the product will melt back and be ruined. The temperature and pressure can then be increased in subsequent cycles until signs of collapse or meltback are observed, indicating that the product is too warm. Surprisingly, the inventors found that the collapse temperatures of some samples of P1 were higher than those of their standard coffee products.

[0200] [Table 6]

[0201] Samples were prepared using 10 g of coffee dissolved in 40 g of water at 85° C. Complete dissolution was achieved by stirring with a 25 mm stir bar at 150 rpm for 2 minutes.

[0202] These samples were measured using a Discovery HR-2 rheometer with a sample volume of 8 ml and a circulating bath set at -4 °C for 0.01–1000 s. -1 The samples were tested at temperatures of 20 and 65°C and at concentrations of 1.5 and 20 wt%.

[0203] The data are then fitted to the Quemada model, which is based on the theory of internal structural unit (SU) suspensions and provides insight into fluid rheology.

[0204] Within concentrated systems, single particles and small agglomerates can form increasingly larger groups, the size of which depends on the applied shear rate.

[0205] Viscosity (η) is therefore a function of structure (η=f(s)), which depends on the level of applied shear (as increased shear rate simply acts to disperse the macro- and mesostructure of the aggregates into individual subunits), and viscosity can be expressed in terms of packing fraction / density, since the more densely packed the SUs are, the higher the packing fraction and, consequently, the higher the structure (viscosity).

[0206] This is because the density of SUs contributes to the density of the structure.

[0207]

number

[0208] It is noted that at 65°C (close to the consumption temperature) and 20 wt% (i.e., concentrated samples), samples 4 (Milicano) and 7-10 have significantly higher η. This indicates a lower shear rate (1 s ) which is representative of chewing and reflects mouthfeel. -1 From a microstructural point of view at these low shear rates, these samples have more structure than the other samples, which means that at these low shear rates, there is a higher density of these structural units, i.e., a better packing of the structural units.

[0209] The tribology of the samples was also observed. "Tribology is the science and engineering of interacting surfaces in relative motion. It involves the study and application of the principles of friction, lubrication, and wear." Therefore, the parameter of interest was μ, which represents the maximum friction observed for each sample. max in Lubricity is used herein to refer to mouthfeel and max The higher the value, the lower the lubrication. This indicates that the flavor will become less palatable, which is thought to mean a decrease in palatability.

[0210] At 65°C (dissipation temperature), samples 7, 8 and 10 had μ max The value is significantly lower and friction is low. The exception was sample 9 (Robusta blend) which had a lower oil content.

[0211] Determination of surface oil content of soluble coffee powder The sample is extracted by Soxhlet extraction and the oil content is weighed.

[0212] Device Soxtherm Gerhardt Extraction Unit Multistat Soxterm Service Unit Air oven / circulating oven @105°C±2°C chemical balance Desiccator containing silica gel

[0213] Materials and Consumables Gerhardt Extraction Beaker G_Nr.13-0050 Coffee filter (No. 4) Thimble, 33 x 80 mm (S&S 603). raw cotton

[0214] reagent Hexane boiling point range 40-60°C, AR grade (also known as hexane).

[0215] Analysis of samples Place the extraction beaker in a drying oven at 103°C for 1 hour. Remove from the oven and allow to cool in a desiccator. ·Weigh the extraction beaker to four decimal places (M1). Weigh out 5 grams of the dried sample (M2) and place it into a No. 4 coffee filter paper, fold it together, and place the filter into the thimble, leaving a 5 mm space, and place the cotton wool plug on top. · Carefully place the raw cotton plug on top. Place the thimble into the weighed extraction beaker. Fill the extraction beaker with 150 ml of n-hexane Place the filled extraction beaker into the Soxtherm device Extract it using the Multi-Stat Program Base Unit (15 min extraction boil, 30 min (total analysis time 1 hour 17 min) After extraction, remove the thimble. The residual hexane in the extraction beaker was gently blown off with compressed air and further evaporated in an oven at 105°C for 1 hour. After cooling, weigh the extraction beaker containing the resulting oil (M3).

[0216] Resulting Expression

number

[0217] Unless otherwise indicated, all percentages herein are by weight.

[0218] Although preferred embodiments of the present invention have been described in detail herein, those skilled in the art will recognize that changes may be made thereto without departing from the scope of the invention or the appended claims. For example, certain embodiments provide the following: (Item 1) 1. A method for producing coffee powder, comprising: a) providing an aqueous coffee extract comprising 30-55% by weight of soluble coffee solids and 1-10% by weight of oil, said aqueous coffee extract consisting of water and coffee-derived components; b) subjecting the aqueous coffee extract to a two-stage homogenization process to obtain a homogenous coffee extract, the first stage being carried out at a pressure of from 200 to 1000 bar and the second stage being carried out at a pressure of from 10 to 100 bar; c) spray drying the homogeneous coffee extract. (Item 2) 2. The method according to claim 1, wherein the aqueous coffee extract comprises 1.5 to 5% by weight of coffee oil. (Item 3) the aqueous coffee extract is an aromatized coffee extract, the aqueous coffee extract comprising: (i) providing roasted and ground coffee; (ii) contacting the roast and ground coffee with water to form a coffee composition; (iii) subjecting the coffee composition to an aroma separation step to recover a coffee aroma fraction and to form dearomatized roast and ground coffee, wherein the aroma separation step recovers 1 to 15 wt. % of the coffee composition as the coffee aroma fraction; (iv) subjecting the dearomatized roast and ground coffee to one or more aqueous extraction steps to obtain an intermediate coffee extract having 35 to 70% by weight coffee solids; (v) adding said coffee aroma fraction to said intermediate coffee extract to form said aromatized coffee extract. (Item 4) 4. The method according to claim 3, wherein the aromatized coffee extract contains the coffee aroma fraction and the intermediate coffee extract in a weight ratio of coffee aroma fraction to intermediate coffee extract of 2:5 to 1:20. (Item 5) the roasted and ground coffee provided in step (i) has an average particle size of 100 to 600 micrometers; step (ii) comprising mixing the roast and ground coffee with water to form a first slurry containing 15 to 30% by weight of coffee solids; The dearomatized roast and ground coffee is a dearomatized slurry. Item 3. The method according to item 3 or 4. (Item 6) Step (iii) is (A) passing the dearomatized slurry through a first filtration device at a temperature of 90 to 150°C to form a first coffee extract and a first filter cake; (B) adding water to the first filter cake to form a reconstituted slurry having at least 12% by weight coffee solids; (C) heat-treating the reconstituted slurry at a temperature of 150 to 205°C; (D) then passing the heat-treated reconstituted slurry through a second filtration device to form a second coffee extract and a second filter cake; (E) combining the first and second coffee extracts to form a third coffee extract; (F) concentrating the third coffee extract to form the intermediate coffee extract. (Item 7) Item 7. The method according to Item 6, wherein the water in step (ii) and / or step (B) has a temperature of 80 to 100°C. (Item 8) 8. The method according to claim 6, wherein the reconstituted slurry formed in step (B) has a solids content of 12 to 30% by weight. (Item 9) 9. The method according to any one of items 6 to 8, wherein the second filter cake is subjected to a further high temperature extraction process to obtain a further coffee extract, which is combined with the first and second coffee extracts in step (E) to form the third coffee extract. (Item 10) 10. The method according to any one of items 1 to 9, wherein the method further comprises packaging the coffee extract product. (Item 11) 11. The method according to any one of items 1 to 10, wherein the method is a continuous process. (Item 12) 1. A spray-dried coffee powder for forming a coffee beverage, comprising: the powder comprises particles comprising soluble coffee solids and insoluble coffee solids, the insoluble coffee solids comprising coffee oil and an insoluble coffee sediment fraction that is a non-oily portion of the insoluble coffee solids; the powder comprises at least 6% by weight of the insoluble coffee sediment fraction, the insoluble coffee sediment fraction comprising 1% by weight or less of arabinose as analyzed after acid hydrolysis; the powder comprises at least 0.8% by dry weight of coffee oil; and A spray-dried coffee powder wherein said particles exhibit less than 20% by weight of surface coffee oil based on the total weight of coffee oil. (Item 13) 13. Spray-dried coffee powder according to item 12, wherein the powder when reconstituted in water has a particle size distribution of oil droplets with a D50 oil droplet size of less than 7 micrometers, preferably between 1 and 5 micrometers, more preferably between 2 and 4 micrometers. (Item 14) Item 14. The instant coffee composition according to item 12 or 13, wherein the composition comprises 7.5 to 15% by weight of the insoluble coffee sediment fraction. (Item 15) 15. The instant coffee composition according to any one of items 12 to 14, wherein the insoluble coffee sediment fraction contains 0.5 to 1% by weight of arabinose, analyzed after acid hydrolysis. (Item 16) 16. The instant coffee composition according to any one of items 12 to 15, wherein the powder comprises 1 to 5 wt. % coffee oil on a dry weight basis and / or the particles exhibit less than 15 wt. % surface coffee oil, preferably less than 10 wt. % surface coffee oil, based on the total weight of coffee oil. (Item 17) 17. The spray-dried coffee powder according to any one of items 12 to 16, obtainable by the method according to any one of items 1 to 11.

Claims

1. A spray-dried coffee powder for forming a coffee beverage, comprising: the powder comprises particles comprising soluble coffee solids and insoluble coffee solids, the insoluble coffee solids comprising coffee oil and an insoluble coffee sediment fraction that is a non-oily portion of the insoluble coffee solids; the powder comprises at least 6% by weight of the insoluble coffee sediment fraction, the insoluble coffee sediment fraction comprising 1% by weight or less of arabinose as analyzed after acid hydrolysis; the powder comprises at least 0.8% by dry weight of coffee oil; and A spray-dried coffee powder wherein said particles exhibit less than 20% by weight of surface coffee oil based on the total weight of coffee oil.

2. A spray-dried coffee powder as described in claim 1, having a particle size distribution of oil droplets with a D50 oil droplet size of less than 7 micrometers when the powder is reconstituted in water.

3. A spray-dried coffee powder as described in claim 2, having a particle size distribution of oil droplets with a D50 oil droplet size of 1 to 5 micrometers when the powder is reconstituted in water.

4. A spray-dried coffee powder as described in any one of claims 1 to 3, wherein the powder contains 7.5 to 15% by weight of the insoluble coffee sediment fraction.

5. A spray-dried coffee powder described in any one of claims 1 to 4, wherein the insoluble coffee sediment fraction contains 0.5 to 1% by weight of arabinose when analyzed after acid hydrolysis.

6. A spray-dried coffee powder described in any one of claims 1 to 5, wherein the powder contains 1 to 5 weight % coffee oil on a dry basis.

7. A spray-dried coffee powder described in any one of claims 1 to 6, wherein the particles exhibit less than 15% by weight of surface coffee oil, based on the total weight of coffee oil.

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