Roasting unleashes a coffee’s potential; it is  part science part art and lots of good judgment. Roasting requires experience, concentration and precision. The art of roasting is akin to an artist’s signature on a painting, as roasting imprint the roaster’s signature on the coffee.

How bright or muted will a particular coffee be at different roast colors? How much chiaroscuro should the roaster impart to the coffee core flavor? These questions and many more are part of a roasters daily life.

Roasting with too much heat makes the beans too dark with too much caffeol (a fragrant oil produced by roasting when burnt); not enough and the caffeol is not precipitated.

Green coffee beans feel like rounded pebbles and are very hard but after roasting they become much softer and can be easily cracked by a light squeeze. They grow much larger as well, anywhere between 50-80% depending on the beans size, density and the roast color after roasting.

There are many different kinds of coffee roasters.  A classic type of roaster is the Drum Roaster which has a rotating metal drum operated by hot surfaces with heated air passing through the rotating and tumbling beans. Achieving the right balance between the conduction and convention during the roasting process is no small task but is one which is very rewarding.

The second most common roaster is the Thermal Roaster.  This type operates strictly by convection where the beans typically float on a bed of hot air and avoid touching hot surfaces. This type of roaster permits a very clean expression of the coffee flavor profile though it lacks the dimensionality that is produced in drum roasters–which impart a slight roast variation between surface and interior–achieving more depth and highlighting acidity.

During the roasting process the green coffee beans are roasted at temperatures ranging from 350º F – 460º F for 8 to 18 minutes, depending on the degree of roast required and the beans’ size and density.

During the roasting process moisture is lost from the beans, you can hear this happening, the queue is the distinct audible pops the beans makes.

Pyrolysis during roasting is a process in which starches are converted into sugar, proteins are broken down and the entire cellular structure of the bean is altered.

The roasting process develops a fine coffee’s complexity of over 600 flavor components and precipitates the release of caffeol which is the essence of the coffee we enjoy in the cup. Since it is also volatile and water soluble, once the coffee beans have been roasted, the flavor can be damaged by moisture, light and especially oxygen.

Soluble or ‘instant’ coffee was invented in 1901 by Japanese-American chemist Satori Kato of Chicago but was not marketed commercially until 1938. Since then quality and diversity have grown dramatically. Soluble coffee has a number of advantages including speed of preparation, lower shipping weight and volume, long shelf life and being relatively inexpensive.

Soluble coffee is manufactured, just like any other coffee, from ground beans and is commercially prepared by either freeze-drying or spray drying methods. The first stage involves the preparation of a coffee concentrate from which the water is removed, either by heat, known as spray dried, or by freezing, to produce a soluble powder or granules. During the process of dehydration, the coffee essences may be lost, but these are captured and returned to the processed coffee.

Instant coffee is available in powder or granulated formats contained in multiple packaging solutions. The strength of the yielded beverage is determined, by adding more or less powder to the water.  Soluble coffee is a convenient way for preparing iced coffee as it instantly dissolves even in cold water.

Soluble Coffee Production

The green coffee beans are first roasted to bring out their flavor and aromas. Once roasted the beans are then finely ground. Grinding is performed in order to allow the coffee to be put in solution with water for the drying stage.  Once roasted and ground, the coffee is dissolved in water. This stage is called extraction. Hot water is added and this concentrates the coffee solution to about 15–30% coffee by mass. If required this may be further concentrated before the drying process begins by either vacuum evaporation or freeze concentration.

Freeze Drying Soluble Coffee

The principle of freeze drying is the removal of water by sublimation. Although it is sometimes more expensive then Spray Drying, it generally results in a higher-quality product.

1. The ground wet coffee granules are rapidly frozen.
2. Frozen coffee is placed in the drying chamber.
3. A vacuum is created within the chamber.
4. The drying chamber is warmed.
5. The previously condensed frozen water in the coffee granules expands to ten times its previous volume. The removal of this water vapor from the chamber is critical component in the freeze-drying process.
6. The freeze-dried granules are removed from the chamber and ready to be packaged.

Spray Drying

Spray drying is preferred to freeze drying in some cases because of its economy, short drying time, and usefulness when dealing with such a heat-sensitive product and the fine, rounded particles it produces.

Spray drying produces tiny spherical particles by using nozzle atomization through high speed rotating wheels. The use of spray wheels requires that the drying chambers have a wide radius to avoid the atomized droplets collecting onto the drying chamber walls. One drawback with spray drying is that the particles it produces are too fine to be used effectively by the consumer; they must first be either steam-fused or by belt agglomeration to produce particles of suitable size.

When we think of coffee freshness, we tend to gravitate to the flavor of fresh roasted-coffee.  More often than not, you will taste the traditional flat flavor of “stale” coffee in most homes or businesses. There is another aspect “Stale coffee flavor“ that isn’t mentioned often enough, that is the flavor of staleness originating from the green beans mishandling prior to roasting.

The taste of truly fresh harvested and then roasted coffee will open your taste buds to a new world of coffee flavors and will revolutionize your perception of quality coffee and the true meaning of fresh coffee.  Barrie House Coffee is at the leading edge of setting standards for how green coffee is sourced, transported and stored leading to truly great all around fresh coffee.

Causes of green coffee staleness?

After coffee beans are dried and uniformly processed to the accurate degree of moisture content, they contain the maximum amount of volatile aromatic oils locked within their cellular structure and their flavor is at their peak.  Next to nothing has ever been done to preserve this highpoint instead it has been all about the mere acceptability of a commodity fulfillment.

Green coffee is shipped and stored in woven jute or sisal bags and most of the commodity green coffee purchased is stored and circulated for over a year before it will be roasted, this in turn devolves the green coffee that is exposed to oxygen, environment conditions and to the bags structure themselves.

What characterizes green coffee staleness?

First is the evaporation of the coffees’ aromatic oils, these are the core of any fine coffee’s unique flavor signature. The next to go is sweetness, while lignin, which forms the cell walls of the coffee bean and is the chief non-carbohydrate constituent of wood, ages and imparts an ever-increasing flavor of aged cedar wood. This is the common flavor style found in most specialty coffee establishments today.

How to solve the raw green coffee staleness problem?

Solving the raw green coffee staleness problem requires changes by roasters purchasing and handling procedures, as well for an ongoing education by all parties involved in the coffee sourcing & selling supply chain of their consumers, on fine coffee and the availability windows for it in its peak flavor.

The final step to producing a harvest-fresh coffee experience is proper storage and smart buying techniques combined with extra scrutiny at the cupping approval level.  As Latin American and East African coffees age, from the time they were harvested last winter, to the coming winter, the difference between a well stored and sourced coffee and all others widens.

We firmly believe the added labor and cost is well worth it and our methodology allows our customers to enjoy nearly a year-round full appreciation of harvest-fresh coffees.

As consumers begin seeking the exotic coffee flavor spectrum of single-origin coffees, a new world of regional coffee offerings will emerge. We believe that by keeping these coffees as limited time offers while at their peak only will empower the craftsmanship of farmers through economic sustainability with dignity by allowing them to sell their coffees at a premium and not as a commodity driven product.

Flavoring oils are mostly combinations of natural and synthetic flavor chemicals which are compounded by professional flavor chemists.

Natural oils used in flavored coffees are extracted from a variety of sources such as vanilla beans, cocoa beans, and various nuts and berries. Cinnamon, clove, and chicory are also used in a variety of coffee flavors.

Synthetic flavor agents are chemicals which are manufactured on a commercial basis. Flavor chemists blend many such oils to achieve specific flavor combinations. While other food flavors may be composed of nine or 10 ingredients, coffee flavors require up to 80 different compounds. An ideal flavor should mask some of the harsh notes of the coffee yet not interfere with its aromatic characteristics. Virtually any taste can be reproduced. Most consumers prefer coffee flavors with sweet creamy notes.

The pure flavor compounds described above are highly concentrated and must be diluted in a solvent to allow the blending of multiple oils and easy application to the beans. Common solvents include water, alcohol, propylene glycol, and fractionated vegetable oils. These solvents are generally volatile chemicals that are removed from the beans by drying. The current flavoring essences technology uses stable solvents which leave the beans with a glossy sheen and longer lasting flavor.

The flavor chemicals and the solvents used in flavors must not only be approved for use in foods, but they must also not adversely react with the packaging material and the processing equipment with which they come into contact.

When coffee is flavored the process begins after the beans are roasted. First the roasted beans  must be quickly cooled before flavorings can be applied. Flavoring the beans while they are still hot can destroy some of the flavor compounds. At Barrie House we perform the cooling step by water misting the hot beans or as we call it ’quenching’. This is a quick process that ensures the desired roast profile will not evolve to a darker shade then desired as a result of thermal heat generated inside the beans during roasting. In addition, we often further cool the beans by jets of cool air.

The appropriate amount of flavoring used is determined before flavor oils can be added to the roasted beans. The amount used typically varies between 2-3%. This amount refers to three pounds of flavor oil added to 100 pounds of roasted beans. The amount of flavoring depends primarily on the type of flavor and its intensity, as well as the type of bean used and its roast level.

he quantity of flavors applied to the beans is largely established by experimental trial and error, in which test batches of beans are flavored with small quantities of oil until the desired characteristics are achieved.

Flavors are typically added to roasted beans before they are ground. The beans are placed in a large mixer which is specially designed to gently tumble the beans without damaging them. The flavors are introduced via a pressurized spray mechanism that breaks the oils into tiny droplets and allows for more effective mixing. Oils need to be added to the beans very gradually to prevent highly concentrated flavor areas called hot spots. The beans are agitated for a set amount of time to evenly distribute the flavor. This process may take 15-30 minutes depending on the batch size and mixing characteristics of the oil. When the beans are properly coated, they take on a glossy finish indicating a uniform distribution of oils.

Flavored coffees must be activated by a sweetener in order to taste them, otherwise you will be taking in the flavor as an aroma.

Possibly the single most important consideration for the sake of freshness and the pursuit of ‘the perfect cup’ is buying your coffee in small quantities, as needed, preferably in whole bean format and grinding it yourself just before brewing.  Proper coffee storage for pre-ground coffee is a tricky affair because the act of storing pre-ground coffee greatly accelerates the staling process. When you grind coffee the entire surface area of the bean’s cellular structure is now exposed to oxygen. So, always buy it in small quantities or individualized packs, and once opened store it in a specialty vacuum canister in a cool dry spot out of direct light and heat.

Certain conditions harm the freshness of your coffee. Below is a list of elements you don’t wish to expose your coffee to.

1. Moisture

2. Oxygen

3. Heat

4. Direct Light

To freeze or not to freeze?

The answer will be a resounding no. It can’t get cold enough to keep your coffee fresh, so what happens is that your coffee will deodorize and dehumidify your refrigerator–just like baking soda, especially if its ground.

Also freezing isn’t recommended because exposure to moisture in the freezer will destroy the precious flavor and aromatic oils within the coffee. Keep in mind, if coffee is penetrated by moisture the essential oils are dissolved, then hot water will not be able to release the coffee flavors in the oils and will yield a weaker flavored cup of coffee.

Recommendations for proper coffee storage

Coffee packaged in our quality bags can be stored in a cool dry place.  Once the bag has been opened, the remaining whole bean coffee can be stored until used up in any of the following ways:

1. Re-seal the bag by tightly folding the bag several turns, then folding over the wire-tie or sealing the top by other means. Gently squeeze out the air that was allowed to enter the bag when it was opened, taking care not to crush the one-way valve or to force out the air too quickly and damaging the valve.
   • If your coffee was fresh, you will notice the bag will seem to re-fill with air over time. This is actually not air, but CO2 being emitted from the freshly roasted coffee. The valve operates only when adequate back pressure needed to open the valve is reached, the CO2 buildup should not be expelled, as CO2 is somewhat inert, and will keep the beans fresher longer, compared to oxygen.
2. Using a vacuum storage container with a built-in pump will probably be one of your best options for keeping your fresh roasted coffee as fresh as possible. The vacuum pump removes nearly all of the air from the canister so that flavor and aroma isn’t spoiled by the presence of oxygen.  Most of these containers are also slightly opaque further protecting the coffee from harmful effects of light.

Drinking coffee is bad for your health – FICTION

Regular coffee drinking can be part of a healthy, balanced diet and lifestyle, and moderate coffee consumption i.e., 3-4 regular cups a day, is safe for most individuals with no adverse effects.   Scientific evidence also suggests that moderate coffee consumption may actually offer a number of benefits. For example, the European Food Safety Authority recently stated that caffeine improves both sports performance (endurance exercise) and increases attention and alertness. Some individuals may choose to switch to decaffeinated coffee e.g., those sensitive to the stimulant effects of caffeine late afternoon/early evening. For these individuals, decaffeinated coffee provides an alternative so they can still enjoy the taste and aroma of coffee.

Drinking coffee doesn’t increase risk of cardiovascular disease –FACT

Moderate coffee consumption is not linked to an increased risk of cardiovascular problems such as heart disease, heart attacks, irregular heart beat or high blood pressure.  Research also suggests that, in both men and women, drinking coffee in moderation may reduce their risk of stroke, but no firm conclusion has yet been drawn.  Coffee’s effect on cholesterol levels is largely dependent on the method of brewing. Filtered coffee is not associated with a significant increase in cholesterol levels, while boiled coffee can raise cholesterol levels.

Pregnant women should stop drinking coffee – FICTION

Studies from the last decade clearly report that moderate caffeine consumption, including that from coffee, is not a matter of concern for a healthy pregnancy. Pregnant women can still enjoy a couple of cups of regular coffee a day.  Health authorities recommend that pregnant women should limit their daily caffeine intake to 200-300mg from all sources. A regular cup of caffeinated coffee contains approximately 80-100mg of caffeine.  Overall, well-conducted scientific studies in humans have shown no adverse effects on the fetus if a pregnant woman consumes a moderate amount of caffeine from coffee or other caffeinated beverages.

Drinking coffee helps improve sports performance – FACT

The effects of coffee consumption on sports performance are linked to the caffeine in coffee, rather than to coffee itself.  The European Food Safety Authority (EFSA) recently stated that a cause and effect relationship has been established for caffeine intake and increased endurance performance, endurance capacity, and a reduction in perceived exertion. Caffeine is effective at doses of 6-8mg/lb.  Caffeine may moderate central fatigue and influence ratings of perceived exertion, pain and levels of vigor, all of which are likely to lead to improvements in performance.

Coffee is dehydrating – FICTION

While there is some indication of a mild, short-term diuretic effect of caffeine, this effect is not strong enough to counter-balance the benefits of fluid intake from coffee drinking.  Scientific evidence looking at the effects of caffeine on fluid balance does not support a significant diuretic effect of caffeine.  Coffee drinking in moderation contributes to our daily fluid intake and does not lead to dehydration, or significant loss of body fluid.

Drinking coffee keeps me alert and helps me concentrate – FACT

The caffeine in coffee is well known for its stimulating effects, which have scientifically proven benefits on mental performance.  The European Food Safety Authority (EFSA) recently stated that a 75mg serving of caffeine (the amount found in approximately one regular cup of coffee) increases both attention and alertness. The stimulant effects of a regular cup of coffee are observed between 15 – 45 minutes after consumption and normally last for about four hours.

Coffee can become addictive – FICTION

While caffeine in coffee is a mild central nervous system stimulant, recent scientific studies using brain scans suggest that moderate coffee drinkers do not develop a physical dependence to caffeine.  Some studies suggest that removing caffeine from the diet suddenly may lead to mild, temporary withdrawal symptoms, like headache, in some individuals. These symptoms can be avoided by a gradual reduction of caffeine intake from the diet over time.  It is likely that people continue to drink coffee because they enjoy its taste and aroma, and recognize it as a behavioral stimulant; and not because of any addictive qualities of caffeine.

Drinking coffee in the afternoon or evening does not always disrupt sleep – FACT

Some people who are sensitive to caffeine find that the mild stimulation of coffee, consumed late in the afternoon or shortly before going to bed, may delay the time it takes them to fall asleep and/or affects their sleep overall. Other people consume caffeinated drinks during the evening and have no problems falling asleep. Anyone who is sensitive to the stimulant effects of caffeine can enjoy decaffeinated coffee during the afternoon and evening instead. It should be noted that there are many other factors, including noise, temperature, and discomfort, that may affect how long it takes someone to get to sleep.

Decaffeinated coffee is healthier than regular coffee – FICTION

There are some circumstances when individuals may be advised to, or choose to, switch to decaffeinated coffee. Pregnant women, for example, are advised to limit their caffeine intake to 200mg – 300mg per day and also those very sensitive to caffeine. For those individuals, decaffeinated coffee provides an alternative so they can still enjoy the taste and aroma of coffee.  In addition, some people find that the mild stimulant effect of caffeine consumed late in the afternoon or shortly before going to bed affects their sleep. In their case, it is well advised to switch to decaffeinated coffee during the afternoon and evening would help avoid sleeplessness and still allow them to enjoy their cup of joe. In other cases, drinking caffeinated coffee has actually been shown to have some health benefits. For example, the European Food Safety Authority recently stated that caffeine improves both sports performance (endurance exercise) and increases attention and alertness.