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Industry Overview
Instant, or soluble, coffee has been widely used for decades because of its convenience and ease of preparation. During the height of its popularity in the 1970s, nearly a third of roasted coffee imported into the United States was converted into instant coffee, with annual sales exceeding 200 million pounds. The report notes that about 15% of coffee consumed in the United States is prepared from instant granules, while improvements in product quality have also helped introduce coffee to cultures traditionally associated with tea consumption.
Since its invention, manufacturers and researchers have focused on improving solubility, aroma, appearance, and taste so that instant coffee more closely resembles freshly brewed coffee. Modern processing produces granules with an appearance closer to ground coffee, while aroma recovery techniques help restore volatile compounds lost during processing.
The coffee industry is dominated by Arabica and Robusta varieties. Arabica is generally milder and commands a higher price, whereas Robusta is more economical to cultivate and is widely used in instant coffee manufacture. For instant coffee production, beans are roasted at temperatures above 300°F (180°C), with moisture content generally maintained at about 7-10%, followed by coarse grinding to facilitate industrial extraction. The report focuses particularly on freeze-drying technology, including extraction, concentration, freezing, sublimation, aroma recovery, packaging, process control, and environmental management.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 30 MT./Day |
| Land & Building (20,000 sq.mt.) | Rs. 19.66 Cr. |
| Plant & Machinery | Rs. 327.10 Cr. |
| Working Capital for 2 Months | Rs. 68.48 Cr |
| Total Capital Investment | Rs. 418.94 Cr |
| Rate of Return | 59% |
| Break Even Point | 35% |
Content Index
- INTRODUCTION
- RAW MATERIALS FOR COFFEE
- GREEN COFFEE PROCESSING
- COMPOSITION OF THE GREEN COFFEE
- B.I.S. SPECIFICATIONS
- COFFEE CONSUMPTION PATTERN AND TRENDS IN INDIA
- MARKET OVERVIEW OF INSTANT COFFEE
- INSTANT COFFEE MARKET GROWTH DRIVERS AND TRENDS:
- GROWTH DRIVERS:
- TRENDS:
- INSTANT COFFEE MARKET PLAYERS PERSPECTIVE:
- COFFEE SECTOR IN INDIA
- THE COFFEE PRODUCTION STATES
- BRANDED COFFEE MARKET IN INDIA
- THE COFFEE TRADE: RETAIL MARKET CONSTRUCT
- PRESENT MANUFACTURERS OF INSTANT TEA AND COFFEE PREMIX
- DESCRIPTION OF INSTANT COFFEE PRODUCTION
- [FREEZE DRYING METHOD]
- GENERAL FLOW SHEET OF INSTANT COFFEE PRODUCTION
- (A) EXTRACTION:
- (B) CONCENTRATION:
- FREEZE-DRYING
- STAGES IN INSTANT COFFEE MANUFACTURE [FREEZE DRYING METHOD]
- THE NINE STAGES OF MANUFACTURING INSTANT COFFEE
- STAGE ONE: DELIVERY
- STAGE TWO: ROASTING
- STAGE THREE: GRINDING
- STAGE FIVE: EVAPORATION
- STAGE SIX: FREEZING
- STAGE SEVEN: SUBLIMATION
- STAGE EIGHT: LOST AROMAS READDED
- STAGE NINE: PACKAGING
- INSTANT COFFEE AND PROCESS
- PROCESS FLOW DIAGRAM OF INSTANT COFFEE
- PROCESSING DETAILS OF INSTANT COFFEE BY FREEZE DRYING METHOD
- AROMA IS RECOVERED MAINLY BY TWO METHODS
- FREEZE DRYING AND ITS PRINCIPLE
- STAGES OF FREEZE DRYING
- PRETREATMENT
- FREEZING AND ANNEALING
- STRUCTURALLY SENSITIVE GOODS
- PRIMARY DRYING
- SECONDARY DRYING
- FREEZE DRYING PRINCIPLES
- FREEZE DRYING PRINCIPLES
- SUBLIMATION CONSIDERATION
- FREEZE DRYING PROCESS
- CLEANING-IN-PLACE
- REFRIGERATION
- PROCESS CONTROL
- POLLUTION CONTROL IN COFFEE PROCESSING INDUSTRY
- CHARACTERIZATION OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
- TABLE: EFFLUENT STANDARDS-SUGGESTED RANGE FOR POLLUTANTS
- DISCHARGE INTO INLAND SURFACE WATERS
- SOURCES OF WASTEWATER:
- FIG: WATER BALANCE DIAGRAM
- ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
- COFFEE IS PROCESSED IN TWO WAYS:
- TREATMENT OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
- WATER RECYCLING:
- FIG: FLOW CHART ILLUSTRATING WATER RECYCLING PROCESS
- FIG: WATER RECYCLING MECHANISUM
- CONVENTIONAL TREATMENT METHODS:
- IT HAS 3 TANKS:
- FIG: SCHEMATIC FLOW SHEET OF WASTE WATER TREATMENT UNITS
- EQUALIZATION TANK:
- ANAEROBIC TANK:
- AEROBIC TANK:
- AIR POLLUTION AND ITS CONTROL IN COFFEE PROCESSING
- A. ROASTING
- B. QUENCHING
- C. COOLING
- D. DESTINING
- E. GREEN BEAN HANDLING
- F. GRINDING
- G. DECAFFEINATION
- H. CONTROL EQUIPMENT
- RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING
- COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:
- FIG: ANAEROBIC TREATMENT SYSTEM
- COFFEE PROCESSING WASTE MANAGEMENT PRACTICE
- TABLE. AFRICA: COFFEE PRODUCTION (AVERAGE IN THOUSAND BAGS OF 60 KG EACH)
- COFFEE INDUSTRY RESIDUES APPLICATIONS
- PROCESSING OF COFFEE
- WET METHOD
- DRY METHOD
- FIG. SUN DRYING OF COFFEE FOR DRY PROCESS
- PROBLEMS OF COFFEE WASTE
- TABLE. HEALTH PROBLEMS REPORTED BY THE POPULATION LIVING NEARBY INDUSTRIES
- MANAGEMENT OF COFFEE WASTE
- TABLE. CHARACTERISTICS OF EFFLUENT WASTEWATER FROM CONVENTIONAL WET COFFEE PROCESSING PLANTS
- ENVIRONMENTAL ISSUES
- TABLE. COMPOSITION OF COFFEE WASTE
- CONCLUSION
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CONDENSER
- SUPPLIERS OF SPRAY DRYERS
- SUPPLIERS OF CENTRIFUGE
- SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
- SUPPLIERS OF PACKAGING MACHINE
- SUPPLIERS OF LABORATORY EQUIPMENTS
- SUPPLIERS OF GRINDER
- SUPPLIERS OF BOILERS
- SUPPLIERS OF STAINLESS STEEL TANKS
- SUPPLIERS OF WEIGHING SCALE
- SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF MILK POWDER
- RAW MATERIALS CALCULATION
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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