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Maker - Product Challenge

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Instant coffee drying Equipment

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Do you know that the famous classical music composer and pianist Ludwig van Beethoven insisted on drinking a cup of coffee made from exactly 60 pieces of coffee beans? Currently, around 50% of the world’s green coffee beans undergo processing through instant coffee manufacturing equipment to produce instant coffee. The process requires roasting, grinding, brewing, and heating to obtain the extract; the coffee extract will either go through a spray drying process or a freeze-drying process.

Instant coffee

Freeze drying is the most gentle and aroma protective method of drying, widely used in the coffee industry, but also with applications in the food industry and pharmaceutical sector. Specialist continuous freeze drying plants are bespoke designed to meet your exact requirements and deliver a superior end product.
<h2>Continuous belt freeze dryer for gentle handling of delicate product</h2>
The Devex continuous vacuum belt freeze dryer is the ideal solution for continuous freeze drying of granulates. It allows gentle batch feeding and discharge via vacuum sluices to preserve product quality and minimize mechanical handling - perfect for delicate products where maximum retention of aroma, taste and colour is vital such as coffee products, pharmaceuticals, fruits and herbs.

A bespoke Devex freeze drying plant can handle the full product cycle: foaming, freezing, granulation, sieving, sublimation inside the belt dryer, ice condensation, heating system and high-vacuum technology.

Continuous belt freeze dryer

Freeze drying is a complex and time-consuming drying process which requires maintaining the quality of the product. It can be a delicate and expensive procedure requiring high levels of hygiene. A pilot freeze dryer designed for product formulation and scale-up workshould thus help maintain the high quality and shape of products too sensitive for conventional drying processes.


<h2>Hygienic freeze drying system maintaining high product quality standards</h2>
Siccadania’s F30 Pilot Scale Freeze dryer is typically used for dehydrating high value goods, such as nutraceuticals, foods, pharmaceuticals and instant coffee. It is a hygienic bulk freeze dryer with an external condenser which can be separated from the drying chamber. It uses electrical heating systems for the sublimation process. This secures a uniform temperature gradient and pressure across the entire tray surface area maintaining the product quality. No matter how complex your products may be, it is designed to provide an optimised freeze-drying solution while keeping in mind the highest levels of hygiene and sanitation.

The pilot scale freezer is especially suitable for preserving most of the coffee flavour while manufacturing instant coffee, maintaining the shape and quality of rehydrated food products and delicately drying probiotic bacteria, enzymes, algae etc.

Pilot scale freeze dryer

Nutraceuticals and dietary supplements can be highly sensitive and need to be protected against external such as temperature fluctuations, oxygen and light. The freeze-drying process for these products requires easy up-scaling parameters such as flow, pressure and temperature.


<h2>High capacity and energy efficient drying solution for nutraceuticals and dietary supplements</h2>
Siccadania’s FD500 provides a modular freeze-drying solution for the process industry. It is a hygienic bulk freeze dryer which offers you high quality and energy-efficiency. It has an external condenser which can be separated from the drying chamber. It comes with electrical heating elements which ensure uniform temperature gradient and pressure across the entire tray surface area. This freezer is virtually maintenance free. It has been configured with special attention to up-scaling parameters such as flow, pressure and temperature to enable easy up-scaling. They are certified with either 3.1, FDA and/or FCM.

The industrial food freeze dryer is suitable for the food, beverage and chemical industries and for drying nutraceuticals and dietary supplements e.g. probiotic bacteria, colostrum, enzymes and allergen extracts.

Industrial food freeze dryer

Freeze drying can be an expensive and cumbersome process. When dealing with nutraceuticals it is essential to ensure that the products are stable, concentrated and have a good shelf life. There is a need for freeze dryers to have a capacity high enough to yield large quantities of the end product through batch production, such as capsules or fortifiers to be added to dried food.


<h2>Save costs with an increased capacity to freeze dry nutraceuticals</h2>
Siccadania’s FD500 offers an automated and continuous freeze drying production, by arranging several FD500 standard freeze dryer units in a system. The modularized and optimized FD500 standard module is perfectly prepared for the automatic loading and unloading of trays. It therefore requires no manual labour. The modules can be customised in a desired and suitable layout to reach your required output capacity. Its capacity can be increased or decreased easily, by adding or removing FD500 dryer units to or from the system. The automation system can handle up to 20 units.

The automatic freeze dry system is thus a cost efficient, high capacity solution which freeze dries your product while maintaining their chemical structure to confirm they still provide the expected health benefits. It is hygienic and easy to maintain making it suitable for freeze drying in the food, beverage and chemical industry and also of nutraceuticals and dietary supplements e.g. probiotic bacteria, colostrum, enzymes and allergen extracts.

Automatic freeze drying system

Plant extracts are vital to functional food preparations. But drying them into solid granules may destabilize their thermolabile compounds and degrade flavors and nutrients. The heat generated by drying solutions poses a risk to the quality of extracted substances.


<h2>Protect heat-sensitive compounds with a gentle dryer</h2>
The DryCab by Bucher Merk adapts vacuum drying for heat-sensitive food ingredients such as plant extracts. Its low-pressure technology applies vacuum from a minimum of 0.5 mbar, shielding compounds from over-exposure. The evaporation capacity ranges from 0.5 kg/h to 250 kg/to adjust to different plant materials.

With a working batch volume rate between 2.5 and 2,500 liters, the vacuum drying cabinet is available from lab-scale to industrial solutions. Its heating plates are designed to reduce dead space and hold an active heating surface up to 88m2.

Vacuum cabinet dryer for plant extracts and functional foods

Extracting the essential acids and compounds from fruits and plants is a complex process. But the drying stage can jeopardize their natural characteristics. The aromas, flavors, and other organoleptic properties of the volatile substances are crucial to producing quality fruit powders and plant extracts.


<h2>Preserve delicate compounds with gentle freeze-drying</h2>
The DryBand system for freeze-drying by Bucher Merk is designed for fragile substances such as fruit powders and plant extracts. The technology treats materials with low-pressure vacuum drying starting from 0.5 mbar, which can go up to  50 mbar.

The belts in the continuous drying system are used in series and products move between the top and bottom for an extended residence time. The freeze-dryer is suitable for lab-scale to large-scale lyophilization with a feeding range of 2 kg/h to 4,000 kg/h n. The system supports automated independent heated zones, and the final section can be adjusted as a cooling zone.

Vacuum belt dryer for instant drink powders

Delicate fruits with high moisture levels, such as berries, risk losing their properties when exposed to drying. Destroying volatile compounds and acids, even under low-impact conditions, leads to a loss of nutrients, flavors, and aromas. Moisture release is critical for extended shelf life, but the technology for making fruit powders must protect the bioactive properties from degrading.


<h2>Maximize retention of volatile molecules in fruit powders and berries</h2>
The Zeodration system by Bucher Merk uses an adsorption method that selectively draws water but retains the natural compounds. The heart of the unit is a reactor made from zeolite, a crystallized clay with a narrow pore diameter. At the same time, this water-trapping material minimizes the release of volatile compounds from fruit and fresh products.

A low-pressure environment of 0.5-30m bar makes the technology suitable for freeze-drying and processing delicate materials like berries, plant extracts, or herbs without compromising their aromas. Meanwhile, the reactor attracts water molecules, reducing residual moisture to 0.5%. Zeodration integrates into vacuum and lyophilization systems and handles batch and belt operations.

Freeze drying system for berries and fruit powders

SiccaDania Group is a world-leading manufacturer of drying, evaporating and mixing technologies in the food &amp; beverage and nutraceutical industries.

In the world’s leading coffee communities, people compete in coffee competitions to determine who is the best barista, who can prepare the best coffee brew or who has the best coffee roasting skills. At first glance, <a href="https://making.com/instant-coffee">making instant coffee</a> seems to be a less popular challenge.

Yet close to <a href="https://en.wikipedia.org/wiki/Instant_coffee">50% of the world's green coffee</a> is used to produce instant coffee. If you would like to bring a premium instant coffee product to the market, you are likely to use <a href="https://www.newfoodmagazine.com/article/16968/freeze-drying-in-the-coffee-industry/">freeze-drying technology</a>. It's gentle drying conditions avoid aroma and color deterioration, as well as nutrient degradation.

&nbsp;


<h2>A freeze dryer to match your coffee brand</h2>
Freeze drying technologies are available for batch or continuous operation depending on your demand or ambitions. A batch process is used for low capacities (generally ranging from 50-7,000kg of powder per day). A continuous process is used for large capacities (generally ranging from 7,000-25,000kg of powder per day). When you prefer to scale up as you go, look for modular set-ups that allow you to extend when demand increases.
<h2>Different steps in freeze drying coffee</h2>
A typical <a href="https://making.com/technologies/industrial-freeze-dryers">freeze drying line</a> will start with a pre-cooling step to control the product color and bulk density. In the following freezing step, you make sure you achieve the right crystal size and structure. The crystals are then grinded into granules and often distributed over trays to be dried in a vacuum chamber. After that, the dried coffee powder needs to be collected from the trays and is ready for packaging. Both batch and continuous plants will need a vacuum pump, a condenser for the water vapour, and a de-icing unit to melt the ice accumulated in the condenser. <a href="https://making.com/equipment/automatic-freeze-drying-system">Reducing operator involvement</a> will help you guarantee the quality of your product when you grow in the market.

[embed]https://www.youtube.com/watch?v=vTM1GHoeo1k[/embed]

Instant coffee, not everyone’s cup of coffee.

Food

A beverage is any kind of liquid or drink, usually other than water, made for human consumption. Beverages are further classified into two categories: alcoholic beverages and non-alcoholic beverages. Alcoholic beverages refer to liquids that contain 1% to 75% of liquor and are produced by fermentation such as wine, beer, or distillation such as vodka, rum, tequila. Non-alcoholic beverages are drinks that don’t have any liquor such as tea, coffee, fruit juices, soft drinks, and carbonated beverages. They can be produced premix or postmix, depending on the setup of your production line.

Beverages

With over one-third of the population consuming it daily in different forms, coffee is one of the most popular processed beverages worldwide. Not only serving as drinks, but coffee is also often regarded as a culture. Coffee manufacturing is a knowledge-intensive industry. Coffee beans from different regions will reveal different tastes, while the level of caffeine could also be different. When it comes to coffee bean processing, the range of roasts varies from light golden brown all the way to dark. The method of tasting coffee differs between countries, habits, and tools.

Coffee

Want a machine to pack unique bag styles such as quad-seal and Doy-pack bags at incredible speeds; this is the machine for you.


<h2>Ultra-fast continuous motion bagger for unique bag styles</h2>
The VikingMašek Continuous Vertical bagger (Sigma 250, Sigma 400) is a fast bagging machine used to pack unique and different bag styles at high speed. The fast-action linear magnetic drives boast over 200 to 220 bags per minute depending on the machine series. With bag dimensions of up to 300 mm to 400 mm wide by unlimited length, plus a host of bag styles like Quad seals and Doypacks at incredible high speeds, the SIGMA is flexible, functional and high-tech machine.

Continuous vertical bagger

If you want to pack into gusseted and pillow style bags and packing speed is important for your packaging process, a continuous bagger with twin sealing jaws could be a good investment.


<h2>The world’s fastest vertical form fill sealing machine</h2>
The VikingMašek Continuous motion bag maker velocity is capable of high speed production up to 300 bpm. The unique center mounted filling tube and natural counterbalanced sealing profiles are designed to provide vibration free, extremely smooth operation at all speeds.

The Velocity is also extremely versatile, handling package sizes up to 300 mm wide and multiple package styles. Patented, independently phased, twin sealing jaws separate the velocity from all other high speed machines and virtually eliminate lost cycle time. This is the world´s fastest bagging machine on the market that has no competition.

Continuous bagger with twin sealing jaws

Hygienic bagging with a compact packing machine that can withstand the harshest wash down processes.


<h2>Ultra sanitary servo driven bagging machine</h2>
The VikingMašek Intermittent Bag maker (ES400) is built to withstand the harshest wash down procedures. This machine has a superior hygienic design and rugged construction. This state-of-the-art vertical hygienic bagger features slanted electrical and pneumatic cabinets, fully stainless steel construction, and an open design for ease of cleaning

This servo-driven bagger is perfect for the hygienic vertical bagging of fresh and frozen fruit, vegetables, and meat/poultry.

Hygienic vertical bagging machine

If you want to pack into unique bag styles like Quad-seal and Doypack, but you don’t require acceleration &amp; deceleration, you can save costs by choosing a bagger with a mechanical drive.


<h2>Steady speed vertical form fill sealing</h2>
The VikingMašek Intermittent Bagmaker series (M250, M400, M500 ) are high-performance vertical form fill and seal machines. Its rugged construction and enclosed jaw drive enables hassle-free packaging in dusty or wet environments.

It can accommodate multiple bag designs and dimensions with high speed and accuracy. It can produce maximum up to 70-100 bags per minute and handles bag sizes from 50 x 60 mm (M250) up to 500 x 600 mm (M500).

This vertical bagger is perfect for packaging quad seal, flat bottom, doy style, brick fold down/tape down, and pillow bags, snacks, candy, coffee, fresh and frozen fruit and more.

Bagger with mechanical driven jaw actuation

<span style="font-weight: 400;">Some say there is no point in drinking decaffeinated coffee. However, decaffeinated coffee can be an excellent solution for those who love coffee but cannot consume caffeine due to health reasons. The central part of making decaffeinated coffee is the caffeine extraction process, which is conducted while the coffee beans are still green. Then, according to the taste profile you intend, you can roast these decaffeinated beans. </span>

Decaffeinated coffee

Filter coffee

<span style="font-weight: 400;">Any coffee-drinker can agree that a cup of coffee in the morning can brighten up their day. As the most convenient way of making coffee, many people choose to make coffee at home. Whether you want to make Moka coffee or filtered coffee, you need ground coffee that is grind appropriately for the coffee brewing method of your choice. These ground coffee are manufactured by roasting and grinding processes. </span>

Ground coffee

VikingMašek is a global leading manufacturer of vertical baggers &amp; multilane packaging solutions.

Coffee is one of the most beloved beverages worldwide, while coffee processing is actually very human-intensive and requires lots of expertise. Packaging plays an very important role in <a href="https://making.com/products/coffee">the coffee production process</a> as coffee is quite sensitive to the exposure of air or other external factors. The right package can not only preserve the flavour and the quality of your products on the journey to consumers' home but also speed up your coffee production process.


<h2>Key factors to consider for bagging your coffee</h2>
After delicately roasting and sometimes grinding, the green coffee has turned into aromatic brown beans and ready to release its flavour. Packaging is really essential as it needs to keep the coffee beans or coffee products fresh and maintain the flavours. Since coffee is really sensitive to external factors such as sun, oxygen or humidity, most formats of package comes with a metalized or aluminum barrier to protect the content. Some pouches or bags will equip with a degassive valve, which will let CO2 out of the bag for the roasted beans.
<h2>Filling coffee products into bags</h2>
When it comes to filling process, it is important to consider the bag design because it can significantly facilitate or slacken the process. For example, if you plan to hand-fill your coffee bags, it is recommended that you choose a bag style that has a wide enough top opening to accommodate your scoop or filling apparatus. On the other hand, automated coffee packaging equipment offers almost unlimited bag options including flat bottom bags, and quad seal bags.

https://www.youtube.com/watch?v=dOJdA1gD92Y

What you need to know about coffee bagging

Find production technology for Instant coffee drying, and connect directly with leading machine manufacturers worldwide