Instant Coffee Extraction with Staged Temperatures for Reduced Process Flavors
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Solution Overview
Problem
Existing methods for producing soluble coffee products result in undesirable processing flavors and a disparity in flavor and mouthfeel compared to freshly brewed coffee, with conventional extraction processes often requiring high temperatures that compromise flavor quality.
Innovation Solution
A method involving a fine grind size of 100 to 600 microns, aroma separation, sequential filtration at controlled temperatures, and a combination of coffee extracts with added aroma fractions to enhance flavor and mouthfeel, while maintaining high yield and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures are used in extraction processes to increase yield, then productivity is improved, but flavor quality deteriorates due to undesirable processing flavors
Solution Approach 1:
The extraction process is divided into multiple stages with different temperature profiles. A first extraction stage uses moderate temperatures (90-120°C) for 5-20 minutes to extract soluble coffee solids without generating processing flavors. A second extraction stage uses higher temperatures (150-200°C) for 1-10 minutes to enhance extraction yield. This segmentation allows the process to achieve high productivity while maintaining flavor quality by avoiding prolonged high-temperature exposure.
Solution Approach 2:
The patent applies preliminary extraction at moderate temperatures before applying high temperature treatment. By performing the initial extraction at lower temperatures for a longer duration, the process pre-extracts the majority of soluble coffee solids without generating undesirable processing flavors. The subsequent high-temperature step then serves to enhance rather than create the primary extraction, achieving high yield while preserving flavor quality.
2Ease of manufacture
If conventional extraction processes are used to produce soluble coffee products, then manufacturing efficiency is improved, but flavor and mouthfeel quality deteriorate compared to freshly brewed coffee
Solution Approach 1:
The patent optimizes multiple parameters including particle size (0.5-2.0 mm), extraction temperatures (90-200°C), extraction times (1-20 minutes), and coffee-to-water ratios (1:5 to 1:20) to achieve superior flavor and mouthfeel. By carefully controlling these parameters, the process produces a soluble coffee product that closely resembles freshly brewed coffee while maintaining manufacturing efficiency through automated extraction systems.
3Productivity
If high temperatures are used in coffee extraction, then extraction yield is improved, but energy consumption increases
Solution Approach 1:
The extraction process segments energy input into two phases: a first extraction phase at moderate temperatures (90-120°C) for 5-20 minutes that extracts the majority of soluble coffee solids with lower energy input, and a second extraction phase at higher temperatures (150-200°C) for 1-10 minutes that enhances yield with higher but shorter-duration energy input. This segmentation optimizes the energy-to-yield ratio compared to continuous high-temperature extraction.
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
The process produces a coffee product with improved flavor and mouthfeel, reduced process flavors, and higher oil content, achieving a thicker consistency and better taste notes, with reduced water usage and energy consumption.
Implementation Method 1
The extraction of roast and ground coffee with water to obtain a high coffee-solids coffee extract is well known
Implementation Method 2
the coffee grounds obtained from the second extraction stage are drained and thermally hydrolysed in a hydrolysis stage at a temperature of 160° C. to 220° C. for 1 to 15 minutes
Implementation Method 3
Soluble coffee solids are extracted from roast and ground coffee in a first extraction stage using a primary extraction liquid
Data Source
AI summary
The present invention provides an instant coffee composition for forming a coffee beverage, wherein the composition comprises at least 6 wt % of an insoluble coffee sediment fraction, the insoluble coffee sediment fraction comprising, when analysed after acid hydrolysis, 1 wt % or less arabinose.