Structure expansion of green coffee beans using instantaneous controlled pressure drop process

Abstract

Since 1988, when the first experiments with the Instantaneous Controlled Pressure Drop (DIC) process were performed, a lot of investigations have been carried out concerning the structure expansion, processing kinetics (drying, extraction and sterilization) and the improvement of the functional and organoleptic properties of fresh and dried foods. In this study, two DIC technologies were used to expand the structure of green coffee beans. Two varieties of commercial Arabica coffee beans of different agricultural and geographical origins (Brazilian and Ethiopian) were inspected. The effect of initial moisture content (7–40% dry basis), type of heating in the DIC process (steam and microwaves), processing parameters like pressure (0.4–0.7 MPa) and heating time (20–200 s) on bean expansion were investigated. The expansion was evaluated as the ratio of the tapped density of raw beans to that of the treated material. The hydration capacity of the beans was also studied. The Response Surface Methodology was employed to optimize the processing parameters. After the steam DIC treatment, the maximum expansion ratio of the Brazilian beans ( e = 1.74) was higher than that of the Ethiopian beans ( e = 1.59). For Brazilian beans, the steam DIC treatment resulted in a higher value of expansion ratio than the MW DIC treatment ( e = 1.39). Concerning hydration capacity, the steam DIC treatment gave values of 78.6% and 48.2% d.b. for the Ethiopian and Brazilian beans, respectively. It means almost two-fold increase in the hydration capacity using DIC treatment. The steam DIC treatment increased and accelerated in twice the weight loss of beans during roasting. Preliminary experiments have shown that the structure expansion of green coffee beans significantly reduced the roasting time, amended the bean suitability to grinding and improved the kinetics and yield of caffeine and active compounds extraction. The industrial DIC processes can be distinguished by high quality of final products, energy saving and positive environmental impact. Due to the fragile structure of coffee beans, a batch process should be applied. Industrial plant can be designed as a tower plant with several compartments separated by guillotine valves where the material falls down by gravity force or a carrousel or a linear plant with filling, DIC treatment and discharging operations. The ABCAR DIC Process Company (La Rochelle, France) develops plants with a capacity of 50 kg/h to 8 ton/h of dry coffee beans. Despite the promising experimental results concerning microwave DIC technology, the industrial applications are so far limited to the steam DIC treatment due to technical reasons.