![Detailed Project Report (DPR) on instant coffee [spray dried and agglomerated]](https://www.eiriindia.org/image/project-report/detailed-project-report-cma-data.png)
Industry Overview
Instant coffee, also known as soluble coffee, is a dried water extract of roasted and ground coffee that produces free-flowing particles of relatively uniform size. Commercial instant coffee primarily consists of soluble coffee solids and is designed to dissolve readily in water. Although instant coffee has existed in various forms for about a century and was included in army rations during the Civil War, it became a widely accepted consumer product after World War II, supported by improvements in manufacturing methods and the growing preference for convenience foods.
The manufacture of instant coffee involves extracting soluble components from roasted and ground coffee using water, followed by concentration and drying. The principal drying technologies are spray drying, vacuum drying, and freeze drying. Spray drying involves atomizing the coffee extract into a stream of hot air or inert gas for rapid drying and is the most widely used method. Vacuum drying produces flakes with high solubility, including in cold water, while freeze drying removes water under high vacuum and very low temperatures to produce a product that more closely resembles brewed coffee, although it involves higher production costs.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 81 MT/Day |
| Land & Building (40,000 sq.mt.) | Rs. 29.12 Cr |
| Plant & Machinery | Rs. 95 Cr |
| Working Capital for 3 Months | Rs. 262.26 Cr |
| Total Capital Investment | Rs. 389.88 Cr |
| Rate of Return | 46% |
| Break Even Point | 30% |
Content Index
- INTRODUCTION
- INSTANT COFFEE
- USES AND APPLICATIONS
- RAW MATERIALS FOR COFFEE
- COFFEE PROCESSING
- COMPOSITION OF THE COFFEE
- B.I.S. SPECIFICATIONS
- MARKET OVERVIEW OF INSTANT COFFEE
- GLOBAL INSTANT COFFEE MARKET OVERVIEW
- COFFEE SECTOR IN INDIA
- THE COFFEE PRODUCTION STATES
- NESTLE'S MARQUEE BRAND HAS MAINTAINED ITS LEADERSHIP IN THE INSTANT COFFEE MARKET
- BRANDED COFFEE MARKET IN INDIA
- THE COFFEE TRADE: RETAIL MARKET CONSTRUCT
- HUL PIPS NESTLE IN INSTANT COFFEE
- PRESENT MANUFACTURERS OF INSTANT TEA AND COFFEE PREMIX
- PRESENT MANUFACTURERS OF INSTANT TEA
- SPRAY DRYING
- ADVANTAGE OF INSTANT COFFEE
- CLASSIFICATION OF INSTANT COFFEE POWDER
- NON-AGGLOMERATED INSTANT COFFEE POWDER
- AGGLOMERATED INSTANT COFFEE POWDER
- GRANULATED INSTANT COFFEE POWDER
- CURING OF COFFEE BEANS
- PRODUCTION METHOD OF INSTANT COFFEE
- TABLE: YIELD (ON DRY BASIS) OF SOLUBLE SOLIDS FROM ROASTED COFFEE
- MANUFACTURING TECHNIQUE OF INSTANT COFFEE
- FIG: FLOW CHART FOR PREPARATION OF AROMATIZED COFFEE
- DRYING TECHNIQUES
- SPRAY DRYING
- NOZZLE TOWER SPRAY DRYER
- FLUIDIZED SPRAY DRYER
- FILTERMAT SPRAY DRYER
- AGGLOMERATED POWDER
- SEQUENCES IN INSTANT COFFEE MANUFACTURE
- ROASTING
- GRINDING
- EXTRACTION
- HOT CELLS
- COLD CELLS
- CONCENTRATION
- THERE THREE METHODS
- VACUUM EVAPORATION
- CENTRIFUGATION
- FREEZE CONCENTRATION
- DEHYDRATION
- METHOD OF PRODUCING INSTANT COFFEE
- FREEZE DRYING METHOD
- SPRAY DRYING METHOD
- PACKAGING
- MANUFACTURING PROCESS OF INSTANT COFFEE
- BLENDS:
- ROASTING:
- GRINDING:
- EXTRACTION:
- THE FACTORS INFLUENCING EXTRACTION EFFICIENCY AND PRODUCT QUALITY ARE:
- DRYING:-
- THE FOLLOWING FACTORS ARE IMPORTANT CRITERIA FOR GOOD INSTANT COFFEE DRYING PROCESSES.
- THERE ARE FOLLOWING TWO PROCESSES FOR DRYING THE INSTANT COFFEE.
- 1. SPRAY DRYING:-
- 2. FREEZE DRYING:-
- PACKAGING:-
- ROASTED COFFEE:-
- INSTANT COFFEE PLANT PROCESSING DETAILS
- 1. CLEANING & BLENDING OF GREEN COFFEE
- GREEN COFFEE CLEANING
- 2. ROASTING & GRINDING OF GREEN COFFEE
- COFFEE ROASTING CUM GRINDING UNIT
- 3. COFFEE EXTRACTION SYSTEM
- COFFEE EXTRACTION
- 4. CLARIFICATION SYSTEM
- CLARIFICATION UNIT
- 5. AROMA RECOVERY CUM CONCENTRATION SYSTEM (ARC SYSTEM)
- AROMA RECOVERY UNIT
- 6. COFFEE CONCENTRATION
- EVAPORATION SECTION - PART 2 CALANDRM SECTION
- 7. SPRAY DRYING SYSTEM
- SPRAY DRYING SECTION
- 8. AGGLOMERATION SYSTEM
- AGGLOMERATION SECTION
- 9. PACKING & FILLING
- PROCESS FLOW DIAGRAM OF INSTANT COFFEE
- FORMULATION OF INSTANT COFFEE (PREMIX)
- INSTANT COFFEE PREMIXED WITH MILK AND SUGAR
- PROCESS FLOW SHEET FOR INSTANT COFFEE PREMIX
- 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. DESTONING
- 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
- METHOD OF COFFEE WASTE INTO RESOURCE
- 1. COFFEE TO COMPOST
- 2. MUSHROOMING FOOD BUSINESSES
- 3. WASTE TO ENERGY
- 4. TEA TIME
- 5. COFFEE FLOUR
- 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
Appendix
- APPENDIX – A:
- 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)
Frequently Asked Questions
Instant coffee is a dried water extract of roasted and ground coffee that dissolves readily in water. It consists primarily of soluble coffee solids and is manufactured to provide a convenient alternative to traditionally brewed coffee. The production process generally involves coffee preparation, roasting, grinding, extraction, clarification, concentration, drying and packaging. Depending on the desired product characteristics, manufacturers may use spray drying, vacuum drying or freeze drying to convert the concentrated coffee extract into a stable soluble product.
Instant coffee is manufactured by roasting and grinding coffee beans, extracting soluble coffee components with water, clarifying and concentrating the extract, and then drying it. Industrial plants may also incorporate aroma recovery systems to retain desirable volatile compounds during processing. The dried coffee can subsequently undergo agglomeration to modify particle size and solubility characteristics before being packed. Process control is important throughout roasting, grinding, extraction, concentration and drying because these stages influence the final product's aroma, flavor, solubility and physical characteristics.
The main drying methods for instant coffee are spray drying, vacuum drying and freeze drying. Spray drying atomizes the coffee extract into hot air or inert gas and provides rapid drying, making it the most widely used industrial method. Vacuum drying produces dried flakes and can provide high solubility, including in cold water. Freeze drying removes water under high vacuum and very low temperatures and generally produces a product that more closely resembles brewed coffee, but the process is more expensive. The selection depends on product quality requirements, process economics and plant design.
An instant coffee plant requires equipment covering raw coffee preparation, roasting, grinding, extraction, clarification, aroma recovery, concentration, drying, agglomeration and packaging. Typical systems include green coffee cleaning equipment, roasting and grinding units, coffee extraction systems, clarification units, aroma recovery and concentration systems, evaporators, spray dryers, agglomeration equipment and packing and filling machinery. Supporting equipment such as boilers, condensers, stainless steel tanks, instrumentation, process controls, weighing systems and laboratory equipment is also important for efficient and consistent plant operation.
The major environmental concerns in coffee processing include wastewater generation, air emissions and management of coffee-related solid wastes. Wastewater can arise from various cleaning and processing activities and may require treatment before discharge or reuse. Air pollution considerations can occur during roasting, quenching, cooling, destoning, green bean handling, grinding and other operations. Appropriate treatment systems, water recycling, emission-control equipment and resource-recovery approaches can help reduce environmental impacts. The report also discusses anaerobic treatment, aerobic treatment, biogas generation, composting and other coffee-waste utilization options.
Agglomerated instant coffee is a form of soluble coffee in which smaller coffee particles are combined into larger, porous particles. Agglomeration is used to modify the physical structure of instant coffee and can improve handling, appearance and dissolution characteristics. It is generally performed after the soluble coffee has been produced and dried, using a controlled process to form the desired particle structure. Instant coffee products may also be classified as non-agglomerated, agglomerated or granulated according to their physical form and manufacturing approach.
Instant coffee quality is influenced by raw coffee characteristics, roasting, grinding, extraction efficiency, concentration, aroma recovery and drying conditions. Extraction must recover desirable soluble components while maintaining the required flavor profile. Roasting and grinding affect extraction behavior and the sensory characteristics of the final product. During concentration and drying, appropriate process conditions are needed to preserve desirable coffee properties and achieve suitable moisture and particle characteristics. Packaging also plays an important role because protection from moisture, oxygen and other external influences helps maintain product stability and quality during storage.
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