Methods of Flavoring Ground Coffee
The phenomenon of gourmet coffee was associated with whole bean varieties in its early stages. Innovations in packaging, such as nitrogen flushing and brick packaging, in conjunction with the maturing of the market allowed ground Arabica coffee to be included in the gourmet sector. Flavored coffee, with nearly 35 percent of sales according to the Specialty Coffee Association of America (SCAA), has been responsible for tremendous growth in the category for many years. Demand for flavored ground gourmet coffee continues to grow, but the methods used to manufacture the product have not in all cases caught up.
Which method of flavoring provides the best cup, necessitates the least contamination of equipment and inventory, requires responsible capital expenditure, and uses equipment which is easy to clean? Fortunately the solution to these questions is within the scope of most roasters flavoring or considers flavoring ground coffee. The scope of this article doesn't address in-store roasting, or on the other side of the scale, the largest multifunctionals. Their needs are often driven by the equipment in place and the need to maintain throughput; but wholesale roasters, large or small, should be able to produce ground, flavored coffee economically, while maintaining the integrity of their non-flavored coffees.
Our tests consistently show that liquid flavor applied to ground coffee provides the best cup. Grinding of previously flavored whole bean coffee through commercial grinders causes flavor loss as the ingredients volatilize due to the heat generated in the grinding process. The smoke you see when grinding flavored coffee beans is the flavor leaving the product. We have also tasted ground coffee prepared with powdered flavors in every available form and from every supplier we have been able to obtain samples from, but they do not perform as well as the liquid applied to ground coffee.
The goal from the manufacturing standpoint is to add the flavor to the coffee as late in the process as possible. This keeps the flavor in the product and avoids contamination of equipment. We recommend flavoring coffee after it has been roasted, ground and gassed off.
Several equipment options are available to mix flavor with ground coffee. The equipment should be made of stainless steel, have easy access for cleaning, should have a motor large enough to provide sufficient torque to move a standing batch of coffee, should provide agitation aggressive enough to disperse the flavor throughout the coffee in a short period of time, and should be easy to load and empty. Ribbon blenders and V-shaped (Patterson Kelly brand) blenders do a fine job. Ribbon blenders are generally less expensive. Both types are usually available as used equipment, still serviceable and at a price considerably less than new.
Processing is quite simple. When using a Ribbon blender, the flavor is added by pouring slowly through a port in the top of the blender while it is running so that the flavor hits the coffee rather than landing on the steel blades which could cause clumping. The coffee is allowed to blend for several minutes and is then removed to the appropriate packaging machine. The V-shaped blender often has a high-speed liquid intensifier bar, a shaft around which the blender rotates. The shaft itself is mounted on separate bearings and spins very quickly on its own motor. The shaft is hollow and has adjustable openings to control the flow of liquid flavors. The rapid spinning of small blades on this shaft creates a vortex which keeps the coffee away from the shaft itself, thus eliminating clumping.
Either machine is also adequate for adding powdered flavors to ground coffee if the roaster is compelled to use this form. In either case, several safety questions must be addressed. The flavoring area should be well ventilated. An exhaust fan will aid of the comfort of the individuals adding the concentrated flavor, and will keep the aroma away from the non-flavored inventory. Eye-protection is essential when working with concentrated flavors. Safety glasses should always be worn. Mixers should be provided with a kill switch that will prevent the motor from running while the mixer is open.
Roasters who have adapted their facilities to flavor coffee using methods similar to those described are enjoying manufacturing ease while witnessing sales growth from a superior product.
William Palmer is vice president of Flavor & Fragrances Specialties, Inc., a manufacturing of coffee flavors in Baltimore, MD.
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