Soluble Coffee Process Reduces Dirty Scum Foam
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Solution Overview
Problem
The incorporation of high levels of roasted ground coffee in instant soluble coffee products can lead to the formation of a dark foam layer, known as 'dirty scum', during beverage preparation, resulting in an unpleasant consumer experience.
Innovation Solution
Incorporating roasted ground coffee after the foaming stage of the concentrated coffee extract and reducing the time before freeze-drying or spray-drying, while maintaining a specific particle size distribution and potentially pre-freezing the intermediate to minimize the extraction of soluble solids, thereby reducing or eliminating the formation of the dark foam layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If roasted ground coffee is incorporated into the liquid coffee concentrate before foaming and freeze-drying, then the soluble coffee product has a more appealing taste and aroma, but a layer of dark foam known as 'dirty scum' forms on the top of the prepared beverage
Solution Approach 1:
The roasted ground coffee is incorporated into the liquid coffee concentrate after the foaming step has already been completed. This preliminary action of adding the ground coffee at a specific stage in the process prevents the extraction of soluble solids that would otherwise occur during mixing and storage before foaming, thereby eliminating the formation of dark foam layer while preserving the beneficial taste and aroma enhancement
Solution Approach 2:
The process minimizes or eliminates the storage time between adding roasted ground coffee and the freeze-drying step. By rushing through the process quickly without extended storage, the extraction of soluble solids from the ground coffee is prevented, thus avoiding dirty scum formation while maintaining the product quality
2Quantity of substance
If roasted ground coffee is incorporated into the liquid coffee concentrate and stored before foaming, then the product has enhanced flavor, but soluble solids are partially extracted from the roasted ground coffee leading to dirty scum formation
Solution Approach 1:
The foaming step is performed as a preliminary action before incorporating the roasted ground coffee. This sequencing ensures that when the ground coffee is added, the foaming structure is already established, and subsequent rapid processing prevents soluble solid extraction that would lead to dirty scum
Solution Approach 2:
The process skips or minimizes the storage period between adding roasted ground coffee and proceeding to freeze-drying. By rushing through this stage without extended storage, the extraction of soluble solids is prevented, thus avoiding the loss of substance that causes dirty scum formation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process effectively reduces or eliminates the formation of the dark foam layer, enhancing the consumer experience by maintaining the quality and appearance of the beverage.
Implementation Method 1
foaming and drying steps to produce a dry granular end product
Implementation Method 2
The pre-freezing (otherwise referred to as cooling) may reduce the pre-frozen coffee intermediate to a temperature of approximately -6°C to -10°C so as to form ice crystals in the intermediate
Implementation Method 3
subjected to various foaming and drying steps to produce a dry granular end product
Data Source
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AI summary
A process of forming a freeze-dried soluble coffee product, comprising the steps of: i) forming a concentrated coffee extract; ii) foaming and optionally pre-freezing the concentrated coffee extract to form a foamed and pre-frozen coffee intermediate; iii) subsequently incorporating finely ground roasted ground coffee into the foamed and pre-frozen coffee intermediate; iv) subsequently freezing the foamed and pre-frozen coffee intermediate to form a frozen coffee intermediate; v) grinding and sieving the frozen coffee intermediate to form a ground coffee intermediate; vi) drying the ground coffee intermediate to form the freeze-dried soluble coffee product. Subsequent to step iii), the foamed and pre-frozen intermediate having roasted ground coffee incorporated therein is subjected to a further pre-freezing step. A process of forming a spray-dried soluble coffee product is also described.