fact higher than those normally obtainable, especially
for decaffeinated instant coffee, so that legal en-
forcement problems rarely arise. The relationship
between the maximum figures for roasted and instant
coffee was originally based upon a purely nominal
extraction yield figure of 33% soluble solids in ex-
tracting roast coffee. It can be seen therefore that a
cup of brewed coffee (from 10 g of roasted coffee) will
contain not more than 10 mg of caffeine, and of
instant coffee (using 2 g of product) 6 mg. (See
Caffeine.)
0003 Decaffeination is the name of the process whereby
caffeine is removed. Almost entirely in commercial
practice the process is applied to green coffee, after
which the decaffeinated green coffee is roasted and
ground, or converted to instant coffee exactly as for
the corresponding nondecaffeinated products. The
composition of these decaffeinated products, apart
from caffeine content, will therefore be almost corres-
pondingly identical. However, there will be slight
differences, and also of flavor, depending upon the
particular decaffeination process employed.
0004 Caffeine is the most studied physiologically active
component of coffee. Though this activity is generally
weak, it has been the subject of numerous publica-
tions and much investigative work. According to the
US Food and Drug Administration in 1984, ‘the evi-
dence received does not suggest that caffeine at pre-
sent levels of consumption poses a hazard to public
health.’
Decaffeination Processes
0005 The various decaffeination processes in use can be
classified with subdivisions in various ways. How-
ever, the original process, still used, is based upon
direct organic solvent extraction of the green beans;
subsequent to that an indirect solvent process was
devised, in which water is first used to remove the
caffeine from the beans, and the aqueous extract is
then treated with the same kind of organic solvent as
before. Since 1970, a variant of direct solvent extrac-
tion has become available in which the solvent is
supercritical carbon dioxide. In all these methods, it
is necessary to be able to recover the caffeine from the
extracting liquids, and generally to refine it to a pure
form for sale. It is also necessary to eliminate all but
traces of organic solvent from the decaffeinated
coffee beans, which should finally have a normal
moisture content of, say, 11% w/w for sale or further
processing. In commercial practice, residues of
organic solvent will be exceedingly small, less than
1mgkg
1
in decaffeinated green coffee and, in a
recent survey by the US Food and Drug Administra-
tion of commercial coffees, less in roasted coffee
(11–640 mgkg
1
) and its brews, and even less
in instant coffee (0.49 mgkg
1
). No particular
legislation for residues has been adopted by European
Community countries, though it has been under con-
sideration for a considerable time now, except that of
the choice of organic solvent which may be used.
0006Decaffeination processes and their offshoots have
been the subject of much patenting activity, since
conventional processes in use can be time-consuming
and complex, and furthermore have led to developing
environmental concerns. Though it can be seen that
residual solvent amounts are negligible in respect of
consumer exposure, use of organic solvents at manu-
facturing sites has to be carefully controlled on ac-
count of various potential hazards. This situation has
prompted the development of alternative processes,
solvents, and caffeine adsorbents.
Direct Solvent Decaffeination
0007The first commercial process was developed and
patented in Bremen, Germany, in 1905, and sold as
Cafe
´
Hag, which name is still in use. The process used
benzene as the solvent upon previously steamed
green beans. However, benzene is both flammable
and toxic, and became replaced by chlorinated hydro-
carbons as they became available, and cheaper.
Trichloroethylene was particularly favored, though
in 1976 it became the subject of US Food and Drug
Administration investigations and was gradually
phased out and replaced by methylene chloride,
which was affirmed for use in 1985 by the above
regulatory body. A number of other organic solvents
have been proposed, though only ethyl acetate and
vegetable oils (including coffee oil and purified spent
grounds coffee oil) have been or are believed to be
used in commercial practice.
0008It was early found that a dry organic solvent
extracted relatively little caffeine, or only very slowly,
from green coffee beans, even though the solubility of
pure caffeine in methylene chloride is reported, for
example, to be 19 g per 100 g of solvent at 33
Cor
1.82 g in trichloroethylene at 15
C. By raising the
moisture of the green beans, first by steaming and
then soaking in warm water, to 20–55% w/w (option-
ally 42% for methylene chloride) at, say, 67
C, the
transfer of caffeine into the solvent is markedly
expedited. The explanation for this effect is twofold:
a swelling of the coffee beans to assist diffusion, and
destabilization of caffeine–chlorogenate complexes in
the coffee bean by heat/water.
0009The extraction itself is carried out in percolation
batteries of five to eight columns (similar to aqueous
extraction in the manufacture of instant coffee,
though not under pressure), though the time of con-
tact can still be as long as 10 h. About 4 kg methylene
COFFEE/Decaffeination 1507