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CA1041354A - Coffee percolation process - Google Patents

Coffee percolation process

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Publication number
CA1041354A
CA1041354A CA213,464A CA213464A CA1041354A CA 1041354 A CA1041354 A CA 1041354A CA 213464 A CA213464 A CA 213464A CA 1041354 A CA1041354 A CA 1041354A
Authority
CA
Canada
Prior art keywords
coffee
roasted
extraction
spent
ground coffee
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA213,464A
Other languages
French (fr)
Other versions
CA213464S (en
Inventor
Saul N. Katz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Foods Corp
Original Assignee
General Foods Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Foods Corp filed Critical General Foods Corp
Application granted granted Critical
Publication of CA1041354A publication Critical patent/CA1041354A/en
Expired legal-status Critical Current

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Abstract

ABSTRACT OF THE DISCLOSURE
A percolation process is described wherein it is possible to operate a fixed-capacity percolator set at decreased capacity without experiencing operational difficulties or coffee extract quality loss. The extraction columns of the percolator set are filled with the amount of roasted and ground coffee desired to be extracted and the remainder of the column is filled with an inert packing material.

Description

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This invention relates to coffee and more particular-ly to a percolation process wherein coffee solids are extracted from roas~ed and ground coffee to produce a cof~ee extract ~ -which is then further processed to form a dry soluble coffee product.
Percolation is the semi-continuous countercurrent -extraction of water soluble coffee solids from roasted and ground coffee. Percolation is performed in a percolator set which is comprised of a series of extraction columns, generally 4 to 6.
At steady-state operation, the extraction columns of the percolator set are ~illed with roasted and ground coffee of varying degrees of extraction or freshness. An aqueous extrac-tion liquid, generally water, is heated and fed to the entrance of the extraction column containing the most extracted roasted ; and ground coffee in the percolator set, generally known as the spent state extraction column. The extraction liquid passes through the spent stage contacting the roasted and ground coffee contained therein and exits the extraction column as a , 20 dilute solution of coffee solids. The extraction liquid is then passed to and through the next successive extraction ` column containing the next most extracted coffee in the perco-lator set, extracting soluble solids therefrom. In like manner the extraction liquid is passed through successive extraction columns containing progressively fresher or less extracted ; roasted and ground coffee. The extraction liquid is finally passed through the extraction column containing the least ex--tracted or freshest coffee in the set, generally unextracted . - .

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coffee, known as the fresh stage extraction column and a pre-determined portion of the extraction liquid is drawn off as cofee extract thus completing a cycle. I'his coffee extract ~`
generally contains from 20% to 35% soluble coffee solids by weight and is then further processed to produce a dry soluble ~;
coffee product.
A new cycle is begun by taking the spent stage ex-traction column off-stream and placing a new extraction column generally containing unextracted roasted and ground coffee on-. . .
stream thus becoming the fresh stage for draw-off of coffee extract in this cycle. Aqueous extraction liquid is then fed ' to the spent stage extraction column for this cycle, the cofee ~
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contained therein being the next most extracted coffee from the . . .
previous cycle, and extraction continues as described above with the extraction liquid contacting progressively fresher ~;
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It roasted and ground cofee.
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~t~ I-t can be seen, then, that a given charge of roasted i,;;
and ground cof~ee becomes progressively more extracted in each , successive cycle.
In commercial percolation processes extraction ; columns are completely filled with roasted and ground coffee and are sized such that the appropriate amount of coffee ex~
~ tract is produced. Further, commercial percolation processes r: are operated at cycle times, i.e., the time between successive draw-offs of coffee extract from the fresh stage, which are `;
~; relatively short so as to more economically produce coffee ex-~;
tract. The coffee extract drying system is similarly fashioned to accommodate the maximum percolation output. The net result of this type operation is a relatively fixed-capacity system.
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However, there often exists the need for operating a given percolator set at capacities below the maximum for which it was designed. It is further essential, of course, that the overall quality of the resultant coffee extract not be diminished.
It has been found that it is possible to operate a ~-fixed-capacity percolator set at decreased capacities without ~--~ encountering operational difficulties or coffee extract quality loss by loading the extraction columns of the percolator set -~
with the amount of roasted and ground coffee to be extracted and filling the remaining area in the column with an inert packing material.
According to the invention ~here ls provided a per-colation process wherein roasted and ground coffee is counter- ;
currently contacted with an aqueous extraction Iiquid in a series of fixedvolume extraction columns, the improvement whereby uniform quality and operating characteristics are obtained at varying output rates, said extraction columns being , . .,,; .
i filled with the amount of roasted and ground coffee to be extracted and filling the remaining areas in said columns with an inert packing material.
Various means of reducing the percolator output result in serious operational difficulties and/or a decrease in the quality of the resultant coffee extract. Loading the ex-traction columns with only that amount of roasted and ground ~; coffee to be extracted leads to extremely troublesome operation. The coffee is loosely packed within the fixed-. .~.
volume extraction column and results in a migration of coffee - particles, particularly those of fine particle size which can si lead to excessive pressure buildups. Further, the packed .~ - .
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~L~4~3~i4 coffee will begin to separate on contact with the extraction ~
liquid and move into the free spaces of the column. The ~ ~;
resultant loss of the packed bed character leads to excessive channelling and bypassing of the coffee which results in .
extremely poor extraction of the soluble solids therefrom.
There resul-ts uneconomical operation and a possible quality decrease since many flavorful coffee solids are left un-extracted.
. :;
While reduced capacity can be achieved using a column 10 completely filled with coffee by utilizing long cycle t:imes, it ;; ;
has been found that operation in this manner is deleterious to the quality of the coffee extract due to the degradation of . , flavorful coffee solids during prolonged contact with hot ex-traction liquid. ;~
According to this invention, however, it is possible to operate the percolator set at reduced capacity without en- -~
.: :
countering any of the above-mentioned problems.
Thus, the percolator set is operated with its extrac- ;
tion columns completely filled to avoid pressure problems and uneconomical operation and at normal cycle times so as to avoid adversely affecting the quality of the coffee extract.
In general, it is possible according to this in-; vention to operate at reduced capacities in the order of about 0.6 the normal fixed-volume capacity. This will require generally the utilization of packing material not in excess of - about 35% by weight of the overall column load.
, ,; . .. ..
The iner-t packing material utilized in the process of this invention should contain little or no extractable material or characteristic color which would adversely affect the flavor ~ .
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and aroma of the ultimate coffee extract. The material should -be capable of being packed within the extraction column with a - minimum of large void spaces. Suitable inert packing materials are the commonly-employed column packings such as ~aschig i rings, Berl saddles, Pall rings, Lessing rings, and the like.
Examples of these are set out in Perry's, Chemical Engineer's Handbook, 18 26 (4th ed. 1963, McGraw-Hill).
A particularly useful and our preferred packing ~;
material is spent coffee grounds defined as roasted and ground coffee which has been fully extracted during the percolation process. The spent coffee grounds should be dried and screened to break up any lumps of material before use in the extraction column. While by definition having little if any extractable material, the spent grounds may impart an undesirable aroma note to the coffee extract in some cases. Accordingly, it is preferred to "dearomatize" the spent coffee grounds prior to ; their use as a packing to remove all such extractable aromas , and/or flavors. This may be suitably accomplished by contact-~,:. . .
ing the spent coffee at temperatures in the range of 200F. to 300F. It may also be preferred to first wash the spent coffee ; grounds to remove any extraction liquid that may be adhering thereon.
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. . .
. The amount of roasted and ground coffee to be ex-tracted and the inert packing material may be interspersed in a ,- random fashion within the extraction column. However, our preferred embodiment of this invention separates the packing material from and roasted and ground coffee which is to be ex-tracted. Preferably, the extraction column is separately ; loaded such that the entering aqueous extraction liquid first ~.
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1~4~13~4 i contacts the inert packing material prior to contacting the roasted and ground coffee to be extracted. Thus, for an extraction column operated in the upflow direction, the requisite amount of inert packing would be loaded into the bottom of the extraction column and then the roasted and ground coffee to be extracted is loaded thereon to fill the column. ;
It is found that this type operation is particularly - .
-~ useful where the inert packing material is spent coffee - grounds. The effect of any aromas from the spent coffee being picked up by the e~traction liquid and drawn off in the coffee extract is minimized by virtue of a "filtering" effect of sorts : which the roasted and ground coffee to be extracted has on these aromas.
Further, regardless of the packing material, opera-tion in the above manner is found to result in more efficient extraction of the roasted and ground coffee by virtue of the fact that uniform flow patterns are developed in the packing before contact with the roasted and ground coffee to be ex-tracted.
The insert packing material may also be alternately layered with the roasted and ground coffee to be extracted or ~: loaded into both the top and bottom of the extraction column.
.i .~. - .
, The roasted and ground coffee to be extracted may be decaffeinated or undecaffeinated coffee and may be a single coffee variety or a blend of coffee varieties. The aqueous extraction liquid, while generally water, may also be any solu-tion of soluble solids such as salts or soluble coffee solids.
The extraction liquid is generally heated to between 300F. to ~ 350F. before being fed to the spend stage extraction column ,:

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and it is generally desired to draw off coffee extract from the fresh stage extraction column at temperatures belGw about 220F. Suitable intercolumn heaters or coolers may be employed according to well-known prior art processes to achieve this or any other desired temperature profile across the percolator set.
The following example will serve to more fully illustrate an embodiment of the process of this inventi~n.
..
EXAMPLE -~
A percolator set comprised of six extraction columns capable of holding 1800 lbs. of roasted and ground coffee at normal operation is operated at a capacity 0.6 times the normal. The extraction columns of the percolator set are first loaded with 100 lbs. of spent coffee grounds and then with 1080 lbs of roasted and ground coffee to be extracted in which is distributed an additional 376 lbs. of spent coffee grounds.
., .
The remainder of the extrac-tion column is filled with 100 lbs of spent coffee grounds. The total column load is 1~56 pounds (owing to the fact -that the spent coffee grounds have a 20%
lower bulk density than the roasted and ground coffee to be extracted) of which 34.8% by weight is spent coffee grounds. .~
The percolator set is then operated at standard cycle times ~ -(about 15 to 30 minutes) without experiencing operating difficulties or a decrease in the quality of the resultant coffee extract.
~:.
~; Numerous other reduced output rates can be achieved ; .:
by varying the amounts of roasted and ground coffee to be ~;
- extracted and the inert packing material. The ability to operate over a wide range of varying output rates greatly ~"
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` increases and enhances the flexibility of the percolation ~system. ;
The spent coffee grounds are prepared for use as the ` packing material in the following manner. A portion of the : . .
spent coffee removed from the spent stage extraction column after completion of a cycle is screened to remove any free ;; liquid and then further washed with water to remove any . , adhering extraction liquid. The wet spent coffee grounds are .~ ~
then fed to a dryer and dried with hot air at about 200F. to :
10 300F. to about 10% moisture. Any lumps of spent coffee grounds are then broken up and the grounds are screened to ; remove those particles which pass through an 8 mesh screen.

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Claims (5)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A percolation process wherein roasted and ground coffee is countercurrently contacted with an aqueous extraction liquid in a series of fixed-volume extraction columns, the im-provement whereby uniform quality and operating characteristics are obtained at reduced capacities in the order of about 0.6 the normal fixed-volume capacity, said extraction columns being filled with the amount of roasted and ground coffee to be extrac-ted and filling the remaining areas in said columns with spent coffee grounds.
2. A process according to claim 1, wherein said packing material does not exceed about 35% by weight of the total column load.
3. A process according to claim 2, wherein said roasted and ground coffee and said filler material are inter-spersed within said extraction column.
4. A process according to any one of claims 1 to 3, wherein said spent coffee grounds are dearomatized spent coffee grounds.
5. A process according to claim 2, wherein said roasted and ground coffee and said spent coffee grounds are separately loaded into said extraction column such that said aqueous extraction liquid entering said columns contacts said spent coffee grounds prior to contacting the roasted and ground coffee to be extracted.
CA213,464A 1973-11-19 1974-11-12 Coffee percolation process Expired CA1041354A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US41731273A 1973-11-19 1973-11-19

Publications (1)

Publication Number Publication Date
CA1041354A true CA1041354A (en) 1978-10-31

Family

ID=23653449

Family Applications (1)

Application Number Title Priority Date Filing Date
CA213,464A Expired CA1041354A (en) 1973-11-19 1974-11-12 Coffee percolation process

Country Status (1)

Country Link
CA (1) CA1041354A (en)

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