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Advancements in Coffee Manufacturing: From Dehydration Techniques to Quality Control

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Food Engineering Reviews
Authors:
Saleh Al-Ghamdi at King Saud University & Washington State University
Saleh Al-Ghamdi
  • King Saud University & Washington State University
Bandar Alfaifi at King Saud University
Bandar Alfaifi
Wael Elamin
Wael Elamin
Wael Elamin
  • This person is not on ResearchGate, or hasn't claimed this research yet.
Mustapha Abdul Lateef
Mustapha Abdul Lateef
Mustapha Abdul Lateef
  • This person is not on ResearchGate, or hasn't claimed this research yet.
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Abstract and Figures

This comprehensive study delves into advanced dehydration techniques and processing technologies in the realm of coffee manufacturing. It offers a comparative analysis of these techniques, specifically focusing on green coffee beans and instant coffee production. The examination encompasses the pivotal steps of grading, roasting, grinding, extraction, and dehydration, which form the core of the coffee manufacturing process. In the context of instant coffee production, two primary dehydration methods, spray-drying and freeze-drying, are scrutinized for their roles in water removal from coffee extracts and slurries and their impact on final product quality and efficiency. This study emphasizes the significance of dehydration processes as the linchpin of manufacturing optimization, considering their prominence in coffee production plants. Furthermore, the research extends to investigate the diverse extraction techniques, additional processes, and critical technologies, such as agglomeration, used in the production of coffee instant powder. Quality control, life cycle analysis, and assurance are scrutinized to provide insights into the overall sustainability of coffee manufacturing. The examination also explores the environmental impact, byproducts, and nuanced properties of coffee powder across different production systems. In essence, this review serves as a valuable resource for industry professionals, researchers, and coffee enthusiasts, offering a holistic understanding of advanced coffee dehydration techniques and their impact on quality, efficiency, and sustainability in the context of both green coffee beans and instant coffee production.
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Vol.:(0123456789)
Food Engineering Reviews (2024) 16:513–539
https://doi.org/10.1007/s12393-024-09383-5
Advancements inCoffee Manufacturing: From Dehydration
Techniques toQuality Control
SalehAl‑Ghamdi1· BandarAlfai1· WaelElamin1,2· MustaphaAbdulLateef3
Received: 29 July 2024 / Accepted: 16 August 2024 / Published online: 14 September 2024
© The Author(s), under exclusive licence to Springer Science+Business Media, LLC, part of Springer Nature 2024
Abstract
This comprehensive study delves into advanced dehydration techniques and processing technologies in the realm of coffee
manufacturing. It offers a comparative analysis of these techniques, specifically focusing on green coffee beans and instant
coffee production. The examination encompasses the pivotal steps of grading, roasting, grinding, extraction, and dehydra-
tion, which form the core of the coffee manufacturing process. In the context of instant coffee production, two primary
dehydration methods, spray-drying and freeze-drying, are scrutinized for their roles in water removal from coffee extracts
and slurries and their impact on final product quality and efficiency. This study emphasizes the significance of dehydration
processes as the linchpin of manufacturing optimization, considering their prominence in coffee production plants. Further-
more, the research extends to investigate the diverse extraction techniques, additional processes, and critical technologies,
such as agglomeration, used in the production of coffee instant powder. Quality control, life cycle analysis, and assurance
are scrutinized to provide insights into the overall sustainability of coffee manufacturing. The examination also explores the
environmental impact, byproducts, and nuanced properties of coffee powder across different production systems. In essence,
this review serves as a valuable resource for industry professionals, researchers, and coffee enthusiasts, offering a holistic
understanding of advanced coffee dehydration techniques and their impact on quality, efficiency, and sustainability in the
context of both green coffee beans and instant coffee production.
Keywords Coffee manufacturing· Dehydration techniques· Green coffee beans processing· Spray-drying· Freeze-drying·
Instant coffee production
Introduction
Coffee, widely acknowledged as the “world’s favorite bever-
age”, plays a significant role in the everyday routines of mil-
lions of people worldwide [1]. The rich aroma and diverse
flavors of coffee have made it a cultural icon, transcending
borders and bridging diverse societies. Apart from its highly
appealing taste, coffee is essential to many facets of human
life. From an economic standpoint, it powers a multibillion-
dollar sector, supporting countless people who work in its
production, distribution, and processing. Socially, it acts
as a spark for meetings, conversations, and relationships,
encouraging interpersonal exchanges and communication.
Furthermore, its chemical complexity has spurred a myriad
of scientific investigations, offering insights into both its
nutritional value and potential health benefits.
The global coffee industry has been experiencing steady
growth in production and consumption over the past few
years, with exports playing a significant role in the mar-
ket’s expansion. The International Coffee Organization
(ICO) reports that, in the 2022–2023 crop year, 168.2
million bags (60kg each) of coffee were produced glob-
ally, a 0.1% rise from the year before. In the forthcom-
ing coffee year of 2023/24, it is anticipated that the total
production will rise by 5.8% to reach 178.0 million bags.
This increase is attributed to Arabica coffee, with output
expected to reach 102.2 million bags, and Robusta coffee,
* Saleh Al-Ghamdi
Sasaleh@ksu.edu.sa
1 Department ofAgricultural Engineering, College ofFood
andAgriculture Sciences, King Saud University, P.O.
Box2460, Riyadh11451, SaudiArabia
2 Department ofAgricultural andBiological Engineering,
College ofEngineering, University ofKhartoum,
P.O. Box321, Khartoum11115, Sudan
3 Research andInnovation, MAFA Rice Mill Ltd, Kano,
KanoState, Nigeria
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