NCA 96th Annual Convention, Scottsdale, AZ, March 1-4, 2007

NCA 96th Annual Convention, Scottsdale, AZ, March 1-4, 2007

What’’s Your Profile?

Presentation Topics
1. Profiling and Profile Roasting
2. Control Elements and Components
3. Variables and Roasting Losses
4. Roast Bean Development and Spectrum of Quality
5. Roast Imperfections
6. Glossary of Terms
 Preparation of Coffee

Cup of Green
Coffee

Cup of Whole Roasted Beans

Cup of Expresso

Green Coffee Roasted Coffee Grinding and Brewing

Schematic Representation Of The Roasting Process

Physical
Changes

Chemical
Reaction
Vo
la
t
M ile
oi M
st at
p ut ur er
In e ia
at l/
H e
Green Coffee Variables Process Variables

Coffee Variety Coffee Variety

Moisture Content Moisture Content
Whole/Ground Beans Whole/Ground Beans
Pretreatments:
–– Decaffeination
–– Mild Treatment

Roasting
Roasting Losses
Losses

Roasted Coffee Properties

Degree of Roast Chemical/Physical Properties
Color Value –– Acidity
–– Extraction Yield
–– Chlorgenic Acid Content
–– Aroma Content
–– Bulk Density, etc.

Quality Aspects

Cup Quality Appearance Digestibility Shelf Life

 Heat Transfer And Motion Of Substances Inside The Bean

With higher temperatures, the pores or the cell structure

will expand as internal pressure increases, resulting in a
flow of gases. The velocity of the gases depends upon
the cell density of the bean and is influenced by the air
pressure surrounding the bean.

In a vacuum, this velocity will increase and in higher

than atmosphere pressure, it will decrease.

Three forms of heat are always present, only their relative

proportions are determined by the different types of
roasters.
Conductive Through contact with hot parts of the
Heat –– container and other beans.
Convection By hot air or other gases surrounding the
Heat –– beans.
Radiant Heat ––Through infra-red radiation.
Whether by air quenching or water quenching, rapid
cooling of the roasted coffee is crucial in bringing the
overpressure inside the beans under control and
preventing excessive loss of aroma.
 Roast Development
Time and temperature profile

1st Crack –– Chemical Changes

–– Physical Changes
2nd Crack –– Chemical Changes
–– Physical Changes
Physical Changes –– Color, Density, Shape, Weight
Water Content
Before Roasting –– 6-15% with avg. of 8-12%
After Roasting –– 4-5% depending on original content
and degree of roast

The first crack is caused largely by the internal pressure on the

bean of up to 8 atmosphere due to the evaporation of water found
in the cell structure of the bean. The crack will be audibly louder
with denser and fresher green beans.
The second crack is due to further expansion from pressures
generated by CO2 gases and coffee oil volatiles.
The audible sound of the second crack differs because of
change in the bean fiber due to the roast progress
 Different
Different Roast
Roast Colors
Colors

Weight Loss (aka Shrinkage)

Light Roast –– 12-14%
Medium Roast –– 15-17%
Dark Roast –– 18-21%
Of this, approx. 84% is water, the rest is gases and chaff
Gases released from the roast and ground coffee are 87% carbon
dioxide, 7.3% carbon monoxide, 5.3% nitrogen, .40% aromatic
volatiles.
Endothermic –– Reactions produced by absorption of heat
Exothermic –– Reactions from chemical changes inside the bean
accompanied by the liberation of heat.
Sugar Caramelization
Condensation
Polymerization
Flavor development occurs primarily in the exothermic stage.
Pyrolysis –– The development of organic products due to
process of heat transfer.
 PROBAT Control Engineering
oC
Profile Roasting %
600 100
oC Supply air
500 90

% Supply air Final roasting temperature

400 80
III

II Reducing stages
300 I 70

0 60 120 180 240 300temperature

Final roasting 360 420 t 60
200

100
Product temperature 20 set values 50
Required profile
0 40
0 60 120 180 240 300 360 420 t
Automatic supply air volume or temperature control according to a
specific profile curve. Suitable for known coffees
 3 Step Standard
Flexible –– Roasting –– Roasting

Reflex Roasting
1
20

2
 PROBAT Control Engineering
Profile Roasting.
Profile roasting allows to follow a predesigned product temperaure
graph for a single coffee or a blend of coffees.

Basic Values:

PRESET-Values
Roasting- Product- Machine Supply-air Supply-air
time temp. factor temp. volume

Calculate Calculate Calculate Calculate

timeslides difference PID Preset Speed

PID Regulator Speed

Burner preset regulator

Product- Supply-air Burner Supply-air

temp. temp. Oel or Gas Fan
PRODUCT-Values Machine
 Roast Imperfections

Total Time/Temperature Scale

Long Time/ Low Temp Long Time/ High Temp
Baked Burnt
Bland Flavor Carbonized
Little Aroma Charcoal
TIME

Short Time/ Low Temp Short Time/ High Temp

Under Developed Scorched Outer

Greenish Under Developed Inner
Raw Nut/Grainy Burnt/Grainy
Sour/Thin Tipped

TEMPERATURE
Spectrum Of Quality Roasts

Baked Burnt
Dark

Medium
TIME

Light

Under Tipped
Developed

TEMPERATURE
 Optimal Roasting - 6 Minutes, RZ

Color 125
Color 130

Color 100
 High Yield Roasting - 1.5 Minutes

Color 110
Color 125

Color 100
 Roasting Time

Short roasting

Increased acidity
Increased body
Decreased bitterness

Increased bulk volume

Increased extraction yield
Increased soluble solids
 Roasting Time

Long Roasting

Decreased acidity
Decreased body
Increased bitterness

Decreased bulk volume

Decreased extraction yield
Decreased soluble solids
Glossary of Terms
Temperature

1. Heat transfer in the coffee bean progresses from the outside to the
inside.

2. The Transport of mass of volatile compounds inversely from the

inside to the outside.

3. Temperature Difference at the beginning of the roasting process

between outer and inner bean layer is 50°C.

4. Only if the bean core temperature is at about 150°C both

temperatures inside and outside gradually become the same.

5. The shorter the roast time, the greater the temperature difference.

6. When roasting coffee, only a pseudo product temperature can be

measured and controlled. The bean pile temperature consists of
surface temperature of the beans and the air temperature within the
roasting compartment. This temperature depends on coffee type,
bean size, roaster type (design), batch size, and position and type of
thermocouple.

7. Specific heat requirements for Arabica coffee at a specific roast

color and with a green coffee moisture of 11.5% is approximately
470kJ per kilogram of green coffee (theoretically).
Glossary of Terms, Cont’’d.
Color
1. When roasting high-altitude area cultivated and grown
coffees, the sequence in color change runs from tender
green to yellow, yellow-brown, light brown, dark brown to
black brown.

2. Coffees that grow in low lands first turn pale, quasi-

colorless, before turning to a yellow hue.

3. Yellow color starts to develop at a temperature of

approximately 130°C.

4. A single Arabica coffee bean is composed of

approximately 1,000,000 single cells.

5. At a specific roast color or degree of roast an audible

cracking (first crack) can be noticed.

6. The weakest areas on the surface of the coffee bean can

found on the flat side of the bean. Fine hairline cracks
form in this area. The first crack is caused by the relief of
the steam pressure from inside the beans. The second
crack is caused by the formation of Carbon Dioxide.
Glossary of Terms, Cont’’d.
Volume
1. The volume of beans expands during roasting.

2. Through the formation of steam and gas there is a high

build up of pressure inside the cells of the bean causing
coffee beans to swell.

3. The permeability of the cell structure i.e., the porocities,

does not allow for the gradual release of steam and the gas
as it develops which causes the expansion of the beans.
Depending on the coffee type, roasting time, and roast
degree, the bean can grow in volume to be double its size.

4. Hard beans, such as Kenya coffee, can be more resistant

and will cause a slower increase in volume in comparison
to a softer bean.

5. There is a tendency in all coffees towards a decrease in

volume for extended roasting times and an increase in
volume at shorter roasting times.
Glossary of Terms, Cont’’d.
Weight Loss
1. Weight loss during roasting, also called shrinkage, is a
loss in substance and can fluctuate depending on the
degree of roast between 12 and 23 percent.

2. The shrinkage is related to the loss of water and chaff, and

also dry substance in form of carbon dioxide, carbon
monoxide, nitrogen, volatile acids, and volatile aromatic
compounds.

3. Water loss makes up the greatest portion of weight loss.

4. In reference to dry substance, the loss of carbon dioxide in

comparison to other compounds is by far the highest.
Glossary of Terms, Cont’’d.
Maillard Reaction
1. It is a non-enzymatic browning process in which reducing
sugars react with amino acids.

2. Most of the aromatic compounds are formed by the

Maillard reaction. The colorants, called melanoidins, arise
from the non-enzymatic browning reaction.

3. In the first phase of the Maillard reaction, the saccharides

react with amino compounds, peptides or proteins for
which reactive multifunctional intermediate products
develop.
Glossary of Terms, Cont’’d.
Pyrolysis
1. It describes the thermal decomposition of complex substances.

2. During pyrolysis, single compounds of coffee substances are

developed as a result of decomposition.

3. Trigonelline, for example, allows pyridine to form.

4. The decomposition of chlorogenic acids leads to phenoles.

5. Coffee oils allow for a slight amount of aldehydes and

carbohydrates.

6. During pyrolysis, carbon dioxide and carbon monoxide are released

and water is formed.

7. Chlorogenic acids in green coffee is destroyed during roasting.

8. Chlorogenic acid is partly responsible for the stimulating effect and

bitter taste of coffee.

9. The decomposition substances formed from Trigonelline during

pyrolysis, such as pyridine, contribute to the coffee aroma.

10. Furfural is a leading substance for steam-volatile aromatic

compounds of the roasted coffee. It produces a pleasant taste which
is caramel-like to woody.

11. The most important acids in raw coffee are quinic acid, malic acid,
and citric acid.
Glossary of Terms, Cont’’d.
Conversion into Caramel
1. Through heating, some of the simple sugars present are
caramelized into browning products.

2. Browning products are created from the splitting of water

which belongs to the furan group.

3. A typical example of conversion into caramel is the

formation of maltol from fructose.

4. Maltol, which is larixinic acid, is a trypical, pleasantly

caramel-smelling compound which incidentally, is easily
soluble in water.

5. The caramel products contribute, along with the

melanoidins formed in the Maillard reaction, to the brown
color of the coffee beans, i.e., the coffee beverage.
Glossary of Terms, Cont’’d.
Control Components/Elements

1. A proportional integral derivative controller is an instrument to control

burner settings, fan speed, and bean temperature of the roasted coffee as it
develops over time.

““P”” or Proportionate Compensation determines how aggressively the

controller or the system will approach a set point.

““I”” or Integral determines the value by which the temperature is slightly raised
to attain a set point. ““I”” values work in an inverse relation to ““P”” values.

““D”” or Derivative is the value which is used dampen oscillations above a set
point. It is for super fine adjustments. It is less used when using a product
temperature to monitor the roast development.

2. A temperature sensor measures the bean temperature in the roaster. It is a

pseudo-temperature as a mix of product and air.

3. There are other temperature probes installed in the roasting system for air
supply temperature to the beans and exhaust air temperature from the roaster.

4. A program the feeds the PID loop the actual bean temperature profile data and
compares them with the target bean temperature profile data.

5. A profile is a temperature graph of coffee or batch monitoring the

development of the roast process by following time and temperature set points.