0020 More concentrated extracts, say up to 60% w/w
soluble solids, may also be spray dried, though some
controlled foaming of extract with carbon dioxide or
nitrogen gas is then generally required, if the desired
physical properties are to be maintained. (See Drying:
Spray Drying.)
Freeze Drying
0021 Freeze drying has been particularly successful for
coffee extracts, when its use for other foodstuff
liquids/solids has markedly declined in the last
decades. However, a specialized technique has been
developed, first patented around 1965, whereby the
coffee extract is first frozen, and then the slabs are
granulated, whilst still frozen, to particles approxi-
mately the same size as desired in the finished dried
product. Oversize/undersize particles are recycled.
There are a number of designs of freeze drier avail-
able, which will generally handle the frozen granules
in trays resting on heated shelves in a batchwise
manner. The amount of time of freeze drying required
is up to 7 h under a very high vacuum (approx 0.4
torr), and a carefully controlled supply of heat to the
drying granules, by conduction and/or radiation.
0022 Whilst satisfactory product can be obtained by
freeze-drying extracts direct from a percolation
battery, it is more usual for economic and other
reasons for concentrated extracts up to 40% w/w by
freeze concentration (q.v.) or by evaporation (40%
w/w or higher) to be freeze dried. If a favorable bulk
density of 180–220 g l
1
is required, it is additionally
necessary to foam the extract in the slush-frozen
form, before full freezing and freeze drying. (See
Freeze-drying: The Basic Process.)
Separate Volatile Compound Handling
0023 In recent decades, instant coffee manufacture has
become increasingly sophisticated, through greater
attention to methods of maximizing extraction and
retention of volatile compounds responsible for
flavor/aroma, which earlier procedures of simple
extraction and spray drying could not accomplish.
The first method concerns headspace aroma of the
finished powder, due to the presence of very highly
volatile substances that cannot be retained by any
method of spray or freeze drying. A convenient
vehicle was found to be coffee oil, which can be
sprayed or plated (at a level of about 0.5% or less)
on to the powder/granules as already described, and
will give an aroma similar to that of dry roasted and
ground coffee when sniffed. The coffee oil can be that
obtained by mechanical expression of part of the
roast coffee blend to be percolated, or a spent grounds
coffee oil purified and enhanced with suitable
aromatics from other stages of the manufacturing
process. The coffee oil and its aromatics are very
susceptible to oxidation, hence the need for gas-
packed product, as already described. Its application
(so-called ‘aromatization’) will play only a small role
in the flavor of the made-up beverage product, so that
other methods are needed, of which there are many
available, mostly patented. (See Oxidation of Food
Components.)
0024Battery extraction, designed primarily for the ex-
traction of soluble solids, can be fairly successful also
for the extraction of volatile compounds, so that,
when followed by freeze concentration and freeze
drying, a flavorful product is formed. However, vola-
tile compounds can be prestripped by steam from the
roasted coffee before aqueous extraction, in the form
of an aqueous condensate to be reincorporated later.
Similarly, a percolated extract can be stripped of the
important volatile compounds by partial evaporation
(say 10–20% of the water), again to give an aqueous
essence condensate. The stripped extract can then be
further evaporated as required, with the condensate
discarded.
0025The final solution after evaporation containing a
high concentration of solubles, can then be slightly
diluted back with either or both of the aqueous
essence condensates, and used as feed for either
spray or freeze drying. The retention of volatile sub-
stances in spray drying is known to be very markedly
improved when feed extracts of high soluble solids
concentration are spray dried. This will be true also of
freeze drying, though, additionally, it has been found
that parameters of the freezing itself are also very
important (e.g., slow freezing to large ice crystals
favors subsequent volatile retention).
Agglomeration
0026Agglomeration was a process first used for dusty skim
milk powders to increase average particle size and,
more importantly, for ease of rapid dissolution in
water, so-called ‘instantization.’ Whilst the latter is
not required for a satisfactory instant coffee powder,
a similar agglomeration process, using steam/water to
rewet the surface of particles followed by drying, is
used to manufacture instant coffee granules that are
not in fact freeze-dried. Precise details of processes
differ, as the numerous patents will indicate. The
diminution of volatile compound content from spray
drying to granule formation will only be small.
Packing
0027Instant coffee was originally packed into tins but,
since 1960, has now been almost entirely packed
into glass jars. Under EEC prescribed weight
COFFEE/Instant 1497