How Instant Coffee Is Made In Factory

Summary

This video delves into the intricate process of how Nestlé's Nescafé transforms raw coffee cherries into the instant coffee enjoyed by millions. From sourcing premium beans in coffee-growing powerhouses like Brazil and Vietnam, to the advanced technology used in harvesting, processing, and roasting, each step plays a crucial role in achieving perfect coffee. The video highlights the dedication of farmers, the use of innovative machinery, and the careful methods employed in both spray and freeze-drying to lock in flavor. The journey concludes with the packaging of Nescafé's signature granules, ready to be enjoyed in every cup.

Takeaways

• 😀 Instant coffee has evolved since its introduction in 1890, becoming a key part of daily routines for people worldwide.
• 🌍 Nestlé's Nescafé is a leader in the industry, brewing over 1 billion cups of coffee daily.
• 🌱 Over 100,000 farmers in coffee-growing regions like Brazil and Vietnam supply Nestlé with over 13 million bags of coffee beans each year.
• 🍒 The coffee cherries go through a multi-step process, beginning with harvesting when 95% of the cherries are ripe.
• 🚜 Specialized harvesting machines use vibrating rods to quickly gather cherries, improving efficiency compared to handpicking.
• 💧 After harvesting, the cherries undergo a wet mill process, separating ripe cherries from unripe ones using water tanks.
• ⏳ The coffee beans are fermented for 12-24 hours in tanks with clean water to break down the mucilage, preparing them for washing.
• ☀️ Coffee beans are carefully dried under the sun for one to two weeks, ensuring they reach the ideal moisture content of 11%.
• 🏭 Once dried, the beans are hulled to remove the tough parchment layer, revealing the green coffee beans inside.
• 🤖 At the Nestlé factory, advanced robotic systems handle green coffee beans for improved efficiency, preventing injuries from manual lifting.
• 🔥 The beans are roasted at temperatures between 370°F and 540°F, with roasting time impacting the caffeine level and flavor profile.
• 💡 Nescafé uses two drying methods—spray drying for instant coffee and freeze drying for premium Nescafé Gold—to preserve flavor and aroma.
• 📦 After drying, the coffee is packaged into jars, with some factories filling up to 320 jars per minute, sealing in freshness for the consumer.

Q & A

What role does Nestle's Nescafe play in the coffee industry?

Nescafe is a leader in the instant coffee market, brewing over 1 billion cups of coffee every day. It relies on a global network of coffee farmers and cutting-edge factories to produce its products.

How many coffee farmers are involved in supplying beans to Nestle?

Over 100,000 farmers in coffee-growing regions like Brazil and Vietnam supply the beans used by Nestle.

What is the primary function of the coffee cherries in the coffee production process?

The coffee cherries contain the beans, and once they ripen, they are harvested and processed to eventually create instant coffee.

What is the difference between handpicking and machine harvesting of coffee cherries?

Handpicking is a traditional and slow method, while machine harvesting is more efficient, using vibrating rods to shake cherries off the plant, making large-scale operations faster and more cost-effective.

What happens during the fermentation process of coffee beans?

The beans undergo fermentation in tanks, where the mucilage (a slimy coating) is broken down by water. This process lasts 12 to 24 hours and is closely monitored to prevent over-fermentation, which could affect the flavor.

Why is the washing process important for coffee beans?

Washing helps to remove the mucilage from the beans, ensuring they have a clean parchment layer that protects the beans and contributes to their final flavor.

What methods are used to dry coffee beans after they have been washed?

After washing, the coffee beans are spread out to dry on flat surfaces under the sun. Farmers regularly turn them to ensure they dry evenly. The drying process can take one to two weeks.

What is the significance of roasting in the coffee-making process?

Roasting develops the coffee's aroma and flavor. The beans are heated in a rotating drum, with the roast time and temperature affecting the caffeine content and flavor profile, from lighter roasts with higher caffeine to darker roasts with bolder flavors.

How does Nestle's factory ensure the quality of its coffee beans before roasting?

Before roasting, the green coffee beans undergo quality checks, including human tastings to assess their flavor and a sifting process to remove any debris or broken beans.

What are the two drying methods used in the production of instant coffee by Nestle?

Nestle uses two methods to dry coffee: spray drying for Nescafe Originals, which creates granules, and freeze-drying for Nescafe Gold, which retains a premium flavor and texture by locking in aromas through a sophisticated cooling and sublimation process.