SEPARATION TECHNOLOGY PRODUCTION OF INSTANT COFFEE Yield-based coffee extraction plus coffee oil extraction Engineered For Your Success

CONTENTS Highest quality and yield for your instant products Page 02 Perfecting proven processes Page 04 Overview of instant coffee production applications Page 05 Clarification of thin extract and thick extract with the Flottweg separator Page 06 Recovery of valuable raw material with the Flottweg decanter Page 08 Extraction of coffee oil with the Flottweg belt press and Flottweg Tricanter® Page 10 Treating and reducing process wastewater Page 13 High yields even with small production volumes Page 14 Optimizing processes and procedures Page 15 Flottweg quality and service Page 16 ® = registered...

HIGHEST QUALITY AND YIELD FOR YOUR INSTANT PRODUCTS Instant coffee has long since evolved from its niche existence as a coffee substitute and has become a lifestyle product. Countless varieties, flavors, and portion sizes make up this highly attractive and still expanding segment of the coffee market, which brings in tens of billions of euros in Europe alone. However, as its popularity increases, so do the requirements: Consumers don’t just want to be surprised with new recipes, they also want to be impressed by their quality. Instant coffee producers are faced with the challenge of meeting these...

Flottweg is the chosen partner for numerous companies that produce high-quality, flavorful instant coffee on an industrial scale. We support these producers with our separators, decanters, and belt presses. These machines help to increase the quality and purity of the finished (instant) product. In addition, valuable raw materials can be recovered in secondary flows. Flottweg projects stand for absolute customer focus, maximum efficiency, and planning and implementation under the label “Made in Germany”. And they create processes that provide you with a greater overall yield and profitability....

PROCESSES TO PERFECTION The basic principles of producing instant coffee are well-known and proven. Flottweg makes no changes to the basic procedure - we deliver powerful key technologies to support your solid-liquid separation processes. The result: maximum yield, absolute quality, and added value. • Flottweg separators for clarifying thin coffee extract • Flottweg separators for clarifying thick coffee extract • Flottweg decanters for processing the solids discharged by the separator • Flottweg belt press for dewatering coffee grounds • Flottweg wastewater decanters for treating process wastewater...

Overview of instant coffee production applications Coff ffe ee beans Mixing Roasting Grinding Extraction (percolator batteries) Thin extract Coffee grounds dewatering (recovery of residual extract) Flottweg separator Insttanttizattion (freeze drying, sp pray y dry ying g, etc.)) Thick extract Flottweg separator Solids Recovered coffee extract Solids Flottweg decanter Flottweg belt press Press water (coffee oil residual extract mixture) Deoiled and clarified press water Recovered coffee oil Flottweg Tricanter® Flottweg separator Deoiled and clarified press water Wastewater treatment Thermal recycling...

CLARIFICATION CLARIFICATION OF OF THIN THIN EXTRACT EXTRACT AND AND THICK THICK EXTRACT EXTRACT ... ... Soluble coffee or instant coffee blends are obtained by extracting roasted coffee. After blending, roasting, and milling, the coffee is extracted under pressure. The resulting coffee extract solution contains some insoluble components. By removing these components, consumers can enjoy their coffee without any residue in the cup. Flottweg separators are used at precisely this point in the production process: These separators remove all visible particles, thus improving the quality of the finished...

The Flottweg Soft Shot® system • Any combination of partial and full emptying, which means flexible, custom adaptation to the customer's existing process for maximum product yield • Total flush discharge for the removal of tough extract residue, reliable emptying, and maximum cleaning • Material-safe solids discharge that emits almost no sound The insoluble components of coffee extract have a notably viscous, sticky consistency. The quality can vary greatly depending on the blend ratio for the coffee varieties used (proportion of Robusta/Arabica). During separation, these components settle in...

RECOVERY RECOVERY OF OF VALUABLE VALUABLE RAW RAW MATERIALS MATERIALS ... ... A significant quantity of solids is discharged depending on the type of separator, number of clarifiers used, and processing method. This solid material contains valuable coffee extract. As such, it can be worthwhile to further process the solids-extract mixture. To do so, it is first mixed with hot water. A decanter then efficiently separates the solids from this mixture. The resulting very dry solid (up to 50% dry matter content) can be thermally recycled directly. The extract obtained is then returned to the process....

Flottweg Simp Drive® Outstanding recovery rate for coffee extract due to consistently high dry matter content in separated solids High yield even under fluctuating process conditions thanks to fully automatic adjustment of operating parameters High added value with improvement of overall coffee extract yield No blocking of decanter bowl Flottweg impeller • Closed discharge of concentrate under pressure, preventing the formation of foam • Liquid discharged under pressure, avoiding the customary need for a conveying pump • Pond depth can be adjusted during operation, ensuring optimal adaptation...

COFFEE COFFEE OIL OIL EXTRACTION EXTRACTION ... ... The residue from the percolators or extractors, the so-called coffee grounds, contains different amounts of valuable coffee oil depending on the overall process. This oil can be obtained through a two-stage process using Flottweg machines: First the coffee grounds are pressed, then the press water is separated into its component parts. Extraction residue for press water treatment Coffee oil/water mixture Flottweg belt press Flottweg Tricanter® Flottweg separator Solids Solids Deoiled and clarified press water Thermal recycling of solids