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Project Description
This instant coffee extract concentration project is designed to concentrate coffee liquor from the extraction stage, increasing the solid content from approximately 6 wt% to 60–65 wt%. The concentrated extract is subsequently fed into a spray drying system for the production of high-quality instant coffee powder.
Considering the heat-sensitive and foaming characteristics of coffee extract, a four-effect falling film evaporator integrated with Thermal Vapor Recompression (TVR) is adopted for the concentration process.
The system combines gentle vacuum evaporation, multi-effect heat recovery, TVR energy-saving technology, and automatic process control to achieve efficient concentration while minimizing thermal impact on the coffee extract and helping preserve its characteristic flavor and aroma.
Process Technology
Four-Effect Falling Film Evaporation
Coffee extract generally has good fluidity at the initial concentration stage but can be sensitive to prolonged heating. It also has a tendency to foam during evaporation.
For these characteristics, falling film evaporation provides an effective concentration solution. The coffee liquor is evenly distributed at the top of the heating tubes and flows downward along the inner tube walls as a thin liquid film.
This operating principle provides several important advantages:
Short liquid residence time
High heat-transfer efficiency
Gentle evaporation under vacuum
Reduced thermal exposure of the product
Lower risk of excessive foaming and product entrainment
Better preservation of coffee flavor and aroma
The four-effect configuration allows secondary vapor generated in one effect to be utilized as the heating medium for the subsequent effect, significantly improving overall thermal efficiency compared with a single-effect evaporation system.
TVR Energy Recovery & Gentle Heating
To further improve energy efficiency and provide gentle heating for the coffee extract, the evaporation system is integrated with Thermal Vapor Recompression (TVR) technology.
The TVR system uses fresh steam as motive steam to entrain a portion of the secondary vapor generated during evaporation. The two vapor streams are mixed and recompressed to form heating vapor, which is then reused as a heat source for the evaporation process.
By recovering part of the secondary vapor, the TVR system significantly reduces fresh steam consumption and improves overall thermal efficiency. At the same time, the mixed heating vapor provides a moderate and stable heating temperature, reducing the temperature difference between the heating steam and the product.
This gentle heating environment is particularly suitable for heat-sensitive products such as coffee extract, helping minimize thermal degradation and preserve the characteristic flavor and aroma of the coffee while achieving efficient concentration.
Combined with the four-effect falling film evaporation process, TVR technology provides an effective balance between energy efficiency, gentle product treatment, and consistent product quality.
Vacuum Evaporation for Product Quality
The evaporator operates under vacuum conditions, allowing water to evaporate at temperatures below its atmospheric boiling point.
Lower-temperature evaporation is particularly beneficial for coffee extract, as it reduces unnecessary thermal exposure and helps minimize deterioration of heat-sensitive flavor and aroma compounds.
Combined with the short residence time of the falling film design, vacuum operation provides a gentle concentration process suitable for high-quality instant coffee production.
Automatic Operation & CIP Cleaning
The plant is equipped with a fully automated control system designed for stable operation and simplified plant management.
Key automation functions include:
Automatic flow, temperature, pressure, vacuum, and liquid-level control
Automatic concentration process control
Operating parameter monitoring and alarm functions
CIP (Clean-in-Place) cleaning sequence
The integrated automation system reduces manual intervention, improves process consistency, and helps maintain stable product quality during continuous production.
The automatic CIP system enables efficient cleaning of product-contact surfaces without extensive equipment dismantling, supporting the hygiene requirements of food-processing applications and reducing cleaning downtime.
Main Features of the Falling Film Evaporator
Short Residence Time
The falling film operating principle enables rapid evaporation with limited residence time, helping protect heat-sensitive coffee components.
Gentle Vacuum Evaporation
Low-temperature evaporation minimizes thermal impact on the coffee extract and supports better preservation of its natural flavor and aroma.
Efficient Liquid Distribution
The specially designed distribution system ensures uniform liquid-film formation across the heating tubes, supporting stable heat transfer and evaporation performance.
High Heat-Transfer Efficiency
Thin-film evaporation provides excellent heat-transfer performance while reducing unnecessary thermal exposure of the product.
TVR Energy-Saving Technology
Thermal Vapor Recompression recovers part of the secondary vapor and reuses it as heating energy, further reducing fresh steam requirements and operating costs.
Easy Operation and Monitoring
Integrated instrumentation and automatic controls allow operators to conveniently monitor key process parameters and maintain stable operating conditions.
On-line CIP Cleaning
On-line CIP operation simplifies routine cleaning, reduces manual work, and supports hygienic production requirements.
A Reliable Solution for Instant Coffee Production
By combining four-effect falling film evaporation, TVR heat recovery, automatic process control, and CIP cleaning, the system provides an efficient and reliable solution for industrial instant coffee production.
The technology is particularly suitable for applications requiring high concentration ratios, gentle treatment of heat-sensitive products, low energy consumption, stable continuous operation, and consistent final product quality.
From coffee extraction to final concentration before spray drying, the evaporation system is engineered to balance product quality, energy efficiency, operational reliability, and ease of maintenance.
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