Thursday, June 12, 2014

Chaff in Coffee: Causes and Solutions



Q: I notice that I am getting a lot of chaff in the coffee when I drop it into the cooling bin when I finish a roast?

A: The simple answer to this problem is Airflow, Airflow, Airflow.  The complication, however, is determining just where the airflow problem is originating: technique, coffee, weather, drum, blower, internal ducting, or external ducting. 

Technique
In roasters that use a single blower for both roasting and cooling- failure to move the damper from the cooling to the roasting positions can cause a reduction in airflow through the drum and may cause chaff to remain in the drum.  Although

Coffee
Let’s start with the coffee.  Changes in coffee, or increases in the use of certain types of coffees can significantly increase the amount of chaff.  Brazils, Sumatras and Ehtiopian Harrars come quickly to mind.  And while the amount of chaff thrown off by any one coffee should not be an issue in and of itself- increases in the use of these softer bean coffees necessitate an increase in the frequency of cleaning and general maintenance of the roaster.  It is pretty simple really: more chaff, more cleaning.

Furthermore, these coffees are the very ones where you will first notice this problem.  They are not unlike the canaries in the coal mine.  Because they produce more chaff you are more likely to begin to notice airflow problems with these particular coffees.  If you see this problem with these coffees and no others, you still have an airflow problem, and you will eventually see it with other coffees if you do not determine the cause and take the appropriate actions.

Weather
Weather is a problem most experienced by the least experienced roasters, or those that have recently moved a roaster or changed an existing duct.  Thermal inversions, abnormally strong or gusty winds or winds from unusual directions can all cause transient airflow problems with roasters.  The best way to determine if you have an issue with weather is by keeping a roasting log and documenting your weather so that you detect any problem patterns.  If you are experiencing transient weather issues there are several things you may be able to do to lessen, or even eliminate, the problem depending on the particulars of that weather, your exhaust set-up and even the surrounding buildings.  And of course, if you determine that your problem was caused by highly unusual weather, you can always not roast when that type of weather reoccurs. Typical permanent fixes include: extending the height if your exhaust, eliminating horizontal exhaust terminations and changing the termination head of your exhaust.

Drum
Over-packing the drum can cause airflow restrictions that will not allow the chaff to be efficiently pulled off the coffee.  Once again, you will see this most often with the types of coffees mentioned above.  Additionally, darker roasts, because of the increase in bean size can cause an over-packing situation, even if the roaster operates fine with that load size at lighter roasts. However, if this problem is appearing after roasting fine for some time, then over-packing is not the cause, although reducing load size can affect a short term solution.


Blower
The heart of drum and air roasters is the blower.  It is the blower that provides circulation that allows for convective action (the dominate form of heat transfer in both air and drum roasters), and that removes smoke and chaff from the roasted coffee.  For drum roasters insufficient cleaning of the roaster blower is the single greatest cause of chaff remaining in coffee.  This is true because drum roaster blowers move dirty air.  This air contains coffee oils, chaff in varying degrees and green coffee dust.  If allowed to accumulate on the blades of the blower these “dirty” elements will begin to reduce the amount of air that the blower can pull through the roaster and eventually can be reduced to a point where there is no longer enough airflow to pull the chaff out of the drum ( this is also the greatest cause of smoke in the roastery).  How often you clean the blower is mostly dependent upon 5 things:

Type of blower (impeller or squirrel cage)
Exhaust run (how much resistance your blower has to overcome to push out the exhaust)
Type of coffees roasted (see above)
Darkness of roast (the darker the roasts the more blower cleaning that is necessary)
Frequency of roasting (the more often you roast, the more often you need to clean)

Internal Ducting
Internal ducting is generally accepted to be the ducting between the drum and the blower, and may, or may not include the chaff collector, if the chaff collector is internal.  External chaff collectors are considered to be part of the exhaust, except where the blower is mounted atop an external chaff collector, many table top roasters are configured in this manner.

It is important that roasters understand how the air moves within their respective roasting system in order to know how, and how often to inspect/clean this ducting.  The frequency of cleaning internal ducting can be quite long, many roasters do this every year or more, but is very dependent upon the cleanliness of blower.  The dirtier you allow your blower to get the likelier you are to experience a partial or complete clogging of your internal duct.  Complete cleaning of this ducting can be a time consuming and back breaking task.  If you are unsure of how this duct runs, the usual frequency and how to clean it- go back to your manual or ask your manufacturer.

External Ducting
Improper ducting materials or poorly laid out external ducting runs are the second greatest cause of poor airflow through restriction; ducting problems are in fact the greatest cause when roasters experience this phenomenon upon initial installation.  Ducts that have too many angles, long horizontal runs, horizontal terminations, restrictive caps, or are of the wrong size can all cause chaff to remain on the coffee by negatively affecting airflow through the drum. These types of ducting restrictions increase back pressure upon the blower, decreasing the amount of air that can be pulled through the drum.  They can often be noted upon start-up of a new, recently moved, or reducted machine.  

However, these types of restrictions are not always noted at start-up, but they will increase the likelihood of trouble in the future, as well as increase the amount of maintenance that must be performed, especially cleaning of the roaster blower.  Roaster ducts should be inspected, if not cleaned, at the same frequency as the main blower.  When cleaned they should be free of oils, chaff and dust. Mushroom caps, or any cap with screen should be avoided at all costs.  China caps should be modified to allow the air to not be pushed back down toward the open duct.  If at all possible all vertical ducting terminations should use a no-loss or low loss stack head.  (see Ask the Expert Roast Oct/Nov 09).  Horizontal terminations should be avoided, if at all possible.


Most recurring problems with roasters come down to airflow issues.  And chaff on coffee is no different.  Perhaps the most important thing to remember about all airflow issues is that a problem in one area can cause connected problems in another, for this reason it is important to try and understand the flow of air; the flow  through your roaster and through your stack.  If not you may find yourself fixing a problem, only to see it reoccur very quickly.

Bean Probes- Types and Placement



Q:
I am intending to add a bean probe to my roaster and I am confused by the different probes, and where to place the probe to most accurately read bean temperature: can you help?

A:
The widespread use of temperature probes in coffee roasters over the last decade or so, even by “old school” or “artisan” roasters has helped make our industry more professional and safer.  Additionally, it has helped spark the movement toward the profiling of coffee by more accurately, and more quickly, measuring changes along the roast time and temperature curve.  In coffee roasting we are generally discussing 3 types of probes: J type thermocouples, K type thermocouples, and RTDs.  Let’s start with the thermocouples.

Thermocouples (Type Js and Ks)

All thermocouples measure temperature in the same way: by utilizing the known temperature gradient of dissimilar metals.  These dissimilar metal wires are housed within the outer sheath of the probe, most often made of stainless steel.  The heating and cooling of these metals create EMF (electromotive force) that is read as voltage this is then translated into a temperature and read by a repeater, controller or computer.  Both J and K thermocouples work in this manner. The practical difference between a J and a K is the range and therefore the accuracy of each type.  A J type thermocouple can measure up to 1380 F, while a K can measure up to 2300 F.  This means that Js are more temperature sensitive than Ks.  Because coffee seldom sees temperatures much above 470F the more discreet readings of the J are a better fit for use as a bean probe.

So, why use type K thermocouples at all.  Type K thermocouples have their use in coffee roasting operations for the reading of temperatures in afterburners.  The higher temperatures required when operating afterburners are at the very limit of what a J can read and continued operation at this level will eventually cause a J probe failure, making Ks much more practical for this operation.  Also, the more discreet readings required in the coffee roasting process are not needed in the operation of pollution control devices.

RTDs (Resistive Temperature Device)

Resistive temperature devices (RTDs) measure temperature differently from thermocouples: RTDs work by measuring temperature induced electrical resistance across the elements.  Once again the elements are housed in a stainless sheath similar to the thermocouples. 

Type J versus RTD

While either a J type thermocouple or an RTD are well suited for use as a bean probe there are definite and distinct differences between the two.  Below is a quick reference list of differences:

RTD

  • Able to accurately and easily calibrate
  • Easier to bend without damaging
  • More accurate
  • More stable throughout the profile

J Type Thermocouples

  • 2-3 times cheaper than RTDs
  • More durable
  • Responds faster

The increased accuracy of the RTD comes from the linear nature of the temperature vs. resistance plot, as well as their better stability.  Thermocouples on the other hand are decidedly non-linear leading to more drift from profile to profile, this temperature drift decreases stability.  Generally speaking, most roasters using either a basic set point controller (or using a PID controller in this manner), or a repeater are fine with a J type thermocouple.  While many, if not most profile control systems (and better profiling data-loggers) are using RTDs as these systems are more able to capitalize on the increases in accuracy and stability, thereby justifying the increased cost.

At the end of the day, the decision ultimately lies with the owner/operator, as both of these probe types will work well- so long as whatever is being used to read the temperature can accept the signal from the chosen probe type. And, they are placed so that they can measure the surface temperature of the coffee.


Placement for accuracy

At the risk of sounding too obvious, if you want a probe to read bean temperature, then you need to place it where it is in contact with the beans.  In fact, the probe needs to be immersed in the coffee.  For front opening drum roasters this can be a pretty simple part of the process (see drawings).  For certain types of drum roasters, those where the coffee does not ride up against the faceplate; side openers, bottom openers, etc… then some modification maybe needed in order to accurately measure bean temperature, this modification is often accomplished with a funnel shaped catch that allows a mass of beans to surround the probe.   Fluid bed roasters present a special challenge to the measurement of bean temperature as well.  The larger volume of air, and the movement of the coffee within the chamber, while consistent, will read higher temps than drum roasters; making it difficult for fluid bed and drum roaster operators to exchange accurate roasting information.

For front opening drum roasters the probe should be placed somewhere in the lower quadrant of the uptake side of the drum.  For clockwise rotating drums this would be the lower left, for counterclockwise rotating drums the lower right.  If you need to roast smaller batches then the lower you should place the probe in the relevant quadrant.  The most important thing to understand about positioning a probe for accuracy is immersion, and immersion depth.

Immersion Depth

When attempting to place a probe for reading bean temperature it is important to understand where on the probe (or more accurately how much of the probe) the temperature measurement is actually occurring.  Temperature measuring occurs at the end of the probe back and how much of the end of the probe is determined by the diameter of the probe. You want the probe to be immersed in the coffee to a length of 10 times the diameter of the probe.  So, if you have a probe that is ¼” in diameter it should be surrounded by coffee for the last 2 ½” from the tip back.  Likewise, a 1/8” diameter probe needs a 1 ¼” immersion depth.  These depths can be accomplished bending the probe if there is not enough bean mass depth horizontally (see drawing).

Mounting the probe

The mistake most often made when mounting a probe through the faceplate is not using the correct mounting hardware, or not using any hardware at all.  In picture 3 there are 2 Type J thermocouples both with the correct mounting hardware.  This is a threaded compression fitting, one end is threaded into the faceplate and the nut, with the compression barrel is screwed into the fitting.  The barrel tightens against the probe, holding the probe in position.  If a compression fitting is not used, then the force of the coffee pushing against the probe can spin the probe out of position, possibly damaging the probe.  Roasters often will use tape or some type of adhesive to hold a probe in place, this is not recommended as it will loosen and can damage or even destroy the probe.

When positioning the probe, before bending, and or tightening it is important to ensure that you are not contacting either the faceplate, the drum wall (this will throw off your measurements) or the fins and supports for the drum wall (this can destroy the probe).

Bending the probe

It is often the case, as in picture 2 that a bean probe will need to be bent in order to get an accurate and consistent bean temperature reading.  The probe in picture 2 is an RTD, RTDs are easier to bend and can be bent using the thumb as a rest, and bending over the pad of the thumb.  It is more difficult however to bend a Type J thermocouple and care must be taken not to crimp or damage the interior of the probe.  It is best when bending a J thermocouple to use a mandrel (a pulley or rod will suffice) that is at least 21/2 times the diameter of the probe.  Do not attempt to bend a thermocouple without using something to bend around.  With both probes you need to take care not to crimp the probe when bending for a 90 degree angle.

More Accurate Tools, Safer Operation and Better Coffee

Regardless of which type probe you chose, or your reason for choosing it, using a bean probe to help you monitor your coffee during roasting will be one of the best business decisions you will ever make.

Friday, May 30, 2014

Tradition and Innovation

Tradition and Innovation - 5 Part Series “WIRED for ROAST”
THE MODERN SPECIALTY COFFEE business is an industry imbued with tradition and born of innovation. As we North Americans hearken back to the Old World Europeans for coffee continuity, they look to us for new efficiencies. While the coffee-producing nations continue to search for stability from the historical roller coaster that is the green coffee market, Asian countries have begun to create their own unique coffee traditions. Trade secrets are becoming passé and patents all but irrelevant. And new technologies, especially the Internet, are pushing all of us ever closer to one another.
As specialty coffee roasters, we are no different than professionals in a thousand other tradition-bound industries. We sometimes embrace new technological innovations while ignoring others, often without truly grasping the effect these decisions have on our industry and on our businesses.
This is the inaugural article of a five-part series on new technologies and innovations within the coffee industry. It is a series of introductions that will hopefully lead to conversations—conversations about coffee, coffee roasting, specialty coffee markets and how these new technologies will affect our industry as it strives for the perfect cup.
The specialty coffee landscape is quickly changing for roasters and the companies that employ them. Even as new developments in manufacturing and control technologies are changing the way that roasters practice their craft, other areas of the industry are advancing at a more rapid pace. While roasters are busy having the ever-inconclusive debate about art versus science, much of the rest of the coffee world has moved on to embrace new technologies. These changes in other segments of our industry have the potential to impact us in a profound and, in many cases, irreversible manner. Although some roasters recognize what we are seeing, many fail to truly grasp the entirety and totality of the technological changes beginning to occur in other segments of our industry. And perhaps more importantly the great opportunity and the potential threat these technological changes present to roasters of specialty coffee.
Over the next year, this column will cover technological innovations in green coffee and origin, packaging, grinding, brewing, roasting and an assortment of specialized equipment and processes. Trends in the coffee industry will also be covered in cases where they have arisen as a result of new and evolving technologies.
The individual columns are written for professional coffee roasters interested in technological developments within their chosen field. The series will focus mainly, but not exclusively on the specialty side of coffee. It is meant to be complementary with non-technology happenings in specialty coffee, such as the rise of the Roaster’s Guild, the new Roaster’s Speakeasy at the regional Coffee Fests and the ongoing discussions that are happening, both in person and via the Internet, about the changing face of technology in our industry.
Remember, first and foremost this is an introduction, an invitation if you will, to a conversation about tradition and innovation, about technology and specialty coffee, and the connection between these disparate entities. In the spirit of exchange, we welcome suggestions and will entertain and attempt to answer enquiries and criticisms.
--Terry Davis

Thursday, May 29, 2014

Technology Goes to the Beans (Wired For Roast 1)

Technology Goes to the Beans
PERHAPS NO COFFEE SCENARIO is more unnerving to a professional specialty coffee roaster than visiting an account only to be served a truly horrible cup of coffee. As roasters, we can put all our energies into crafting a truly great coffee only to have the whole endeavor go to hell at the end of the supply chain.
As disastrous as that scenario may be, however, a far greater fear is this: that large commercial roasters will figure out how to close the taste gap between specialty coffees and commercial coffees. As coffee consumers' tastes change for the better and specialty roasters continue to erode the market share of the bigger commercial players, these large companies will continue to bring their great resources to bear on the taste deficiencies currently found in their cups.
This article will touch on technologies that have repercussions on both of the above scenarios. On one hand, technology has advanced to allow roasters more and better control over the brewing process, even when it occurs off-site. On the other, technologies are beginning to emerge that allow commercial roasters to try and breach the taste/quality ramparts specialty roasters have so arduously defended through specialty price differentials.

The Espresso Discussion

No other group of coffee people utilizes the Internet to more positive effect than those involved in the evolving discussion over espresso. Through websites, blogs and posting boards, they discuss everything from espresso equipment to single origins, proper espresso roast profiles to specific taste profiles. It is not unusual to find aficionados, baristi, equipment manufacturers, retailers and roasters all lending their opinions, backgrounds and experiences to the developing espresso discussions. These Internet discussions have begun to lead to the use and understanding of at least two tools that attempt to unlock the secret of a great espresso and perhaps more importantly, to reproduce it consistently. These tools, one old and one new, are proportional integral derivative (PID) controllers and espresso machine thermofilter temperature devices, also known as Scace devices.
It has only been a few years since coffee roasters began to use temperature probes and PID controllers to help control the roast process. The widespread adoption of this technology allowed the roasting community to have more substantive exchanges of information and sparked experimentation and innovation in profile roasting that continue to this day. The PID movement within the espresso community is following much the same path. PID controls are beginning to be seen in new espresso machine designs and are an easy and relatively inexpensive upgrade to existing machines.
For most baristi and retailers, the goal is temperature stabilization for a consistent product, but for an intrepid group of coffee professionals and espresso aficionados alike, the accurate and real-time nature of PID controllers is allowing for more and repeatable experimentation of the effects of different extraction temperatures, times and pressures on different origins and blends. More importantly however, may be the development of a common language for the innovators to exchange and verify each other's work.
digital_readout
The second tool is a device that accurately measures water temperature at the brew head. This piece of equipment is named the Espresso Machine Thermofilter Temperature Device, but is commonly called the Scace Device after its creator, Greg Scace.
The Scace Device is a portable troubleshooting tool that marries with existing temperature measuring technology to measure espresso extraction temperatures at an individual group head. The device is deceptively simple and easy to use: one only need purchase the correct size Scace Device for their espresso machine and plug into any number of easily purchased handheld temperature readers, such as a Fluke. Although simple, the development of a puck to mimic the flow rate of a properly tamped and loaded portafilter is truly an ingenious advance in accurate extraction temperature measurement. More importantly for professional roasters, or their representatives, it provides a way to troubleshoot customer's extraction problems, and tweak their machines for maximum flavor extraction with a minimum of labor. Additionally, it can be a valuable tool for experimenting with different espressos in the roasting lab; helping roasters gain a better understanding of the role of extraction temperature upon individual coffees and in extending the specialty roaster's control over the cup produced through their roasting efforts. This tool has the added benefit of being relatively inexpensive as well.

Profile Brewing for Drip Coffee

The technological advances that are occurring on the espresso side are mirrored on the drip brewing side--only in this case, it is profile brewing that is coming to the forefront. "Profile brewing involves manipulating the way water is applied to the grounds producing alternate flavor profiles," says Randy Pope, the head of Bunn's Coffee Lab. For example, applying water at a given rate in the brewing process as opposed to having the water delivered at intervals throughout the cycle (pulse brewing). The differences in the two brewing cycles can significantly affect the taste profile of the individual coffees, resulting in sometimes radically different coffees in the cup.
The idea that different brewing cycles affect the perceived organic acids in brewed coffee (phosphoric, malic, lactic, acetic, citric, quinic, cholorgenic) is not new to roasters. Organic acids, being partially heat-determined, are affected similarly in the brewing cycle and the roasting process. Thus, in both roasting and brewing, time and temperature are the key variables that can be manipulated to produce different profiles. The key words for both processes are control, consistency and repeatability.
This new generation of drip brewers is full of smart elements that help ensure the brewing of better-tasting and more consistent cups of coffee. The most widely adopted innovations include pre-infusion functions, temperature and water regulation, and multi-profile brew settings (brew recipes). Brewer manufacturers currently appear to be in a technology race, each attempting to incorporate and then leapfrog their competitors' latest innovations.
Of all the recent brewer advancements, one of the most interesting is a new system that allows various machines to "talk" to each other. For example, Bunn's new generation BrewWise grinders can write the brewing profile of a specific coffee onto a chip encased in the brew basket. This chip technology then allows the grinder to "talk" to the compatible brewer, telling the brewer what coffee is in the basket and thereby setting the brewing profile for that specific coffee. Additionally, utilizing a PC and a recipewriting program, knowledgeable roasters can gain brew control over all accounts using the same system by simply downloading the recipes onto the brewers and grinders.
And therein lies a serious advancement in the evolution of brewers--the interface of existing PC technologies with the function and form of coffee brewing and grinding. The use of PCs in the process begins to open the door for better communication and data sharing not only between the wholesale roaster and their account, but also eventually between the roasting equipment and brewer itself.
Next up in the gee-whiz brewing category are systems such as the Clover 1, which are designed to bridge the gap between espresso and drip at the retail level. This adjustable brewer is defining a new class of brewer for the retail environment: single-serve. Utilizing a unique press/vacuum brewing method and PID loops, these brewers give the operator direct control over not just brew amounts, but brew times and temperatures, and even allowing for adjustability of water dosage to account for the absorption rates of different coffees and or different roasts. Programmable defaults allow for the "locking in" of preferred brew profiles where time or training prevents operator determined custom cups. In other words, this is a brewer that can brew a custom cup of coffee nearly every time, or create a consistent cup regardless of amount brewed.
The basic concepts involved in profile brewing are fairly simple: time, temperature, fl ow rates, grind size (surface area) and their combined affects on the taste of the coffee in the cup. However, applying the concepts in the everyday world of the professional coffee roaster is still an evolving thing. Determining and "locking in" the correct profiles, as well as the ability to consistently repeat, is where the brewing manufacturers are working now.
Programmable "smart brewers" that can profile brew for different origins and blends are nearly upon us. Time will only tell when and if these technologies come to fruition, and if they gain widespread acceptance in the real world. But one thing is certain--these technologies have the ability to radically change the working environment of the professional roaster. With repeatable, programmable brewers, roasters would have the ability to control the bean from the roaster through to the consumer of the brewed beverage. Matching the inherent taste characteristics of a raw coffee to its optimum roast profile and then on through to the corresponding optimum brew profile is a level of process control that would have seemed fantasy a mere decade ago.
In order to take full advantage of the possibilities that profile brewing presents, more definitive and verifiable taste work needs to be done. Additionally, roasters will need to interface more with brewer manufacturers as well as their own commercial customers, especially specialty retailers. Properly programming brew profiles will require a level of understanding of the brewing process and its effect on taste that few roasters currently possess.
Even as many roasters are still struggling to learn the intricacies of profile roasting, they may find themselves overwhelmed if the promise of profile brewing develops too fast. But, one thing is certain, the science of roasting and the science of brewing are quickly moving toward one another. As roasters, we need to be able to understand the developments in both to help further our comprehensive knowledge of the science of coffee.

Organic Acid Manipulation (The Frankenstein Scenario)

As the development of smart brewers becomes a reality and as roasters and other coffee entrepreneurs learn more about the make-up of the taste of coffee, we have to be cognizant of the possibility of the manipulation of these technologies to "create" coffees.
As early as April 1997, an internal working paper passed between the Specialty Coffee Institute (forerunner of the Coffee Quality Institute) and the Kenya Coffee Research Foundation, comparing levels of phosphoric acids between Kenya's SL28 and other East African cultivars. The intent was to isolate why certain Kenyan coffees had such high relative levels of phosphoric acids, thereby creating a pleasantly sweet cup, and to help farmers eventually reproduce this effect through good agricultural practices. Much good information about organic acids and their role in producing a better cup was obtained through these research efforts. But, one of the more interesting experiments occurred when researchers manipulated the coffees by adding phosphoric acid to a Colombian in amounts that approached those of the vaulted Kenyans.
"Experiments in which phosphoric acid was added to other coffee origin brews significantly altered acid profiles to levels almost identical to Kenyan coffees," says Joseph Rivera, director of science and technology for the SCAA.
In other words, the Specialty Coffee Institute was able to "spike" other origins with enough phosphoric acid to mimic a true Kenyan, even though this was not the original stated intent of their study. Which begs the question: is it possible to buy one coffee and use it as a base to create another more desirable or valuable coffee? Utilizing the correct technology, it appears the answer is yes.
However, creating a coffee in the lab just to see if it can be done, and trying to create coffees economically, are two completely different undertakings. Laboratory-created coffees are not subject to the same market forces that coffees for consumption have to contend with. In order to create a coffee in an economically efficient manner, it would appear to require certain existing technologies: a High Performance Liquid Chromatography (HPLC) system to map the organic acids in brewed coffee and some sort of intelligent or smart brewer that could measure and add these organic acids into the brewing process, perhaps utilizing existing brewer bypass technology. It would also require a mass marketer of brewed coffee to achieve the economies of scale necessary to make such a scenario economically feasible.

Glossary of Terms

High Pressure Liquid Chromatography (HPLC)
A form of liquid chromatography used to separate compounds that are dissolved in a solution. HPLCs are Ideal for separating organic acids within liquid coffee.



Proportional Integral Derivative (PID)
Controller A type of controller utilizing a feedback loop. The output of the controller (CV) is calculated taking into account the error (e) from a user-defined setpoint (SP) and the measured process variable (PV). The PID functions allow for the user to determine the amount of error and to adjust it out, allowing for a high level of stability within a control system.



Programmable Logic Controllers (PLCs)
Small computers programmed to automate specific processes.



Bimodal/Plurimodal Grinding
Allows operators to reintroduce fines into the grind at a desired percentage while still controlling average grind particle size to increase flavor extracted from the coffee. Also called profile grinding.







Two of the three requirements already exist--HPLC and large sellers of brewed coffee--and the third is probably being developed as you read this. The implications of this type of flavor manipulation to the professional coffee roaster could be profound. For growers of certain origins that command premiums for uniqueness, such a development could be disastrous.
However, developments like these are not necessarily nightmare scenarios. A lot depends on who utilizes the technology and for what market(s). If, for instance, a large C-store chain invested in such technology and used it to upgrade the taste of its existing coffee line, the negative affects on the existing specialty market might be negligible, and could possibly have a positive effect by introducing more American consumers to better-tasting coffee, even if that coffee was "created" in the brewer. If a consumer "tasting" a Kenyan created in such a way wished to brew it at home, they would, with existing technology, need to go to the source and buy a true Kenyan in order to come close to the same taste they had been introduced to at the C-store. C-store coffee customers are currently considered to be coffee drinkers that are beyond the reach of the American specialty coffee industry.
There's another possible twist to this futuristic scenario: the development of these technologies for home brewers. It is not beyond the realm of possibility that someday coffee consumers will be able to input the coffee they wished to drink that morning and, regardless of what coffee went into the brewer, out would pop the taste of 2005's Brazil Cup of Excellence winner.
However this scenario plays out, or if it develops at all, it is vitally important that professional coffee roasters be involved in the discussion that is sure to surround it. As much as the use of smart brewers and organic acid mapping to "create" coffees seems beyond the reach of existing technologies, it is not beyond the realm of possibilities. It was not so long ago that genetically modified foods and irradiation of foods for human consumption seemed as far-fetched as creating brewed coffee origins through organic acid manipulation. For many of us this type of technological innovation may have moral and humanitarian implications as well as business and professional ones. It is therefore imperative that roasters of all stripes pay close attention to newly developing technologies if they wish to have a say in the direction that these and other technologies push our industry.

Bimodal Grinding

Often, one technological innovation begets another. Such is the case with bimodal grinding, also often called plurimodal. This advancement in grinding was created as a direct result of the development of commercial espresso pods and the new single-serve capsules. It is an attempt to help get a better and more consistent-tasting product from these newer extraction methods.
So what is bimodal grinding? According to Scott Will, of Modern Processing Equipment, bimodal grinding creates a "grinding methodology, provides a grind, or particle size distribution, that allows users to control not only the average grind size, but also to introduce a percentage of smaller particles, or "fines," into the grinding process to improve coffee extraction characteristics." In roaster terms it is a method for "profile grinding" to obtain a desired extraction result and to ensure repeatability and consistency.
Bimodal grinding allows an operator to select two grind particle sizes in desired mix percentages and combines the grinds for a consistent final product. This allows finer particles to be used to expand the surface area for extraction (chemical need/taste) while using the larger particles to allow for proper water flow (physical need/time) during the extraction process. Once the correct percentages and sizes are known, it is simply a matter of entering the parameters into the programmable logic controller (PLC) automation of the grinder. These new functions allow for the measuring of particle and density size as the ground coffee exits the grinder. Not unlike newer roasting control systems, which seek to use real time measurements to make profile adjustments, this is doing the same, only with grinding instead of roasting. As in roasting, the watchwords in grinding have become control and consistency.
 

FIGURE1

Standard grind distribution for a well-maintained roller grinder.

 figure_1

FIGURE 2

A more desirable particle distribution for an espresso pod application.

 figure_2

FIGURE 3

Results of the bimodal process in action, producing both the "fines" and the primary grinds simultaneously.

 figure_3

FIGURE 4

The final distribution of the grinds measured after blending.
 
figure_4
To most specialty roasters, this type of equipment is well beyond where many of them will go, or even want to go for that matter. It was developed primarily for the espresso pod industry and has applications in the capsule and cartridge coffee delivery systems areas as well. What it does demonstrate however is how serious other segments of our industry are about closing the quality/taste gap as it relates to consumers. It is also worth noting that technology has a tendency to trickle down -- finding more and more applications as the price of components fall and the initial research and development investments are recovered eventually allowing for more companies to utilize the technology in new and exciting ways.
Are we as roasters to fear a future where coffee is created by computer chips embedded in inexpensive home brewers? Or will the future bring an unprecedented amount of control to roasters from plant to cup? Will we as roasters be able to harness and direct the promise of the emerging technologies to move ever closer to the ideal of the "perfect cup"? Or will we be victims of innovations for which we fail to grasp the market implications? The choice, at least in part, will be ours to make.


Extended Readings

Alchemy in the Roasting Lab: The discovery of organic acids, part 1 and 2
Roast magazine, March/April & May/June 2005



Taking Control: PID settings and roasting controls
Roast magazine, March/April 2005



Temperature Control
The Watlow Educational Series Book Five, Watlow Controls, Inc.



Coffee's Acid Test
Coffee & Cocoa International, November/ December 1998







Wednesday, May 28, 2014

A Quick Study (Wired For Roast 2)

A Quick Study - Coffee Earns Its Higher Learning Diploma
AS I SIT HERE putting the finishing touches on this article, my attention is caught by a report on National Public Radio's "Morning Edition" about the correlation between heart attacks and caffeine consumption. The report is on a University of Toronto study that was conducted in Costa Rica to explore whether genetic factors play a role in an individual's susceptibility to caffeine-induced heart attacks.
At first, the report seems like a nice lead-in to this article, which looks at the voluminous amount of research being done on coffee in traditional North American educational institutions. But then the report gets...strange...as in the very next segment--an unrelated report on the economic effects of tuberculosis on underdeveloped countries--an interviewee uses the price of a cup of coffee to illustrate how inexpensively this difficult problem can be overcome. And I am once again reminded of how important coffee is to our world culture.
Coffee, both directly as a food product and indirectly as a language, as a simple source of economic measurement and as an illustration of common relevance to all Americans, is embedded deeply in our culture.
Coffee, as an industry, is a multi-disciplinary undertaking attracting people from many different disciplines: economics, chemistry, agronomy, fine arts, humanities, engineers of all stripes and even the odd nuclear physicist. But it may surprise even experienced roasters to know that there are institutions of higher learning here in the U.S. that actually study coffee, and some that even have whole programs developed around producing and selling coffee. Currently most coffee-related research at United States educational institutions fall into one of three basic categories: health, economics/social science and agricultural/food science.

A Cup of Health

All roasters, if not all Americans, are familiar with the often contradictory health information on the consumption of coffee to human physiology: caffeine is bad for you, caffeine is good for you, lattes will make you fat, the coffee in a latte will help you burn calories, and on and on it goes. As coffee people, most of us could frankly care less about the health effects of coffee, except where it can possibly affect consumer demand. We have been consuming copious amounts of coffee since at least high school and have experienced very few, if any, negative affects so far, with the possible exception of those decidedly sickly feelings of caffeine withdrawal. But health research on coffee could have a huge impact on coffee demand, and for this reason alone, we should be paying attention to these ongoing discoveries.
Coffee and health subjects are extremely varied and cover a wide range of human ailments, both physical and mental. For this reason, if for no other, there are many U.S. research universities looking hard at our favorite drink. Coffee is researched for its possible curative powers for a host of ailments: from different cancers and Alzheimer's disease to gross obesity and severe depression. An inquiring roaster only has to Google coffee and the disease of his choice to find any number of institutions studying coffee's effects on that disease.
As Vanderbilt University Medical Center, home to the Institute for Coffee Studies (ICS), puts it, "Coffee is a complex mixture of potential neutriceuticals" whose chemical composition "is determined by a complex interaction of agricultural factors, roasting, blending, and brewing."
While Nashville, the home of country music, may seem an odd place for serious studies on coffee and health it is, in fact, also the home to ICS, a research organization originally funded by the Association of Coffee Producing Countries (ACPC), the National Coffee Association (NCA) and the All Japan Coffee Association.
As a research organization, ICS's mission is three-fold:
  • to systematically investigate the actions of the various compounds found in coffee using the most advanced biomedical tools
  • to identify potential therapeutic uses of coffee based on fundamental understanding of the pharmacology of its chemical constituents
  • to disseminate research findings and promote educational exchange with partner nations
One of the more interesting aspects of the Vanderbilt program is its focus on the "other" (meaning non-caffeine) compounds found in coffee, especially the chlorogenic family of acids. The researchers seem intent on trying to tease out the effects of caffeine, a known drug, from those that may be attributable to more benign compounds or to the interactions that occur between these other compounds and caffeine, creating a more complex pharmacological effect than that experienced through one compound alone. In order to study and isolate the possible health effects of these non-caffeine compounds, Vanderbilt is also trying to isolate and identify the compounds themselves. This type of core chemistry into the roasted bean may well have spillover into the working roaster's world aside from health.
The Vanderbilt program is important to roasters for other reasons as well: consistency and repeatability. Medical research relies on a peer review process that is exacting about the ability to repeat in order to prove. It is clear that the level of research and provability required of the medical sciences will require a high level of consistency and repeatability from the roasters supplying them with the roasted coffee. This higher level of provability may well have a very positive technological effect on roasters, and may even lead to more research being conducted on the roasting process itself.
Finally, ICS's mission is to discover the possible health effects of coffee consumption. Thus, it studies roasted coffee almost exclusively, making the findings more relevant to roasters.
Of course, no discussion of coffee and health could be complete without discussing caffeine. John Hopkins University School of Medicine, located in Baltimore, has a fairly extensive and ongoing caffeine study program. Although many universities undertake studies of the effects of caffeine on different aspects of human health, including diabetes, pain, gastrointestinal health and cancer, the John Hopkins study is unique because it almost exclusively focuses on the connections between caffeine and mental health.
To quote the John Hopkins mission statement for the Caffeine Independence Program, "Caffeine is the most commonly used mood altering drug in the world...Coffee is the leading dietary source of caffeine among adults in the United States." This makes caffeine a prime candidate for comprehensive and on-going mental health studies. The John Hopkins Medical School study focuses on the following areas:
  • Typical Caffeine Content of Common Foods and Medications: A study of the caffeine contents found in the most common foods and medicines in the American diet.
  • Caffeine and Health: A clearinghouse of sorts for all the health effects associated with caffeine consumption; with a core focus on mental health.
  • Mood-Altering and Reinforcing Effects of Caffeine: Mood-altering effects include both positive and negative reactions, such as mental alertness, sleeplessness, happiness, nervousness, sociability and increased anxiety. Reinforcing effects is a term referring to the ability of a drug to sustain regular drug taking. In other words, you drink coffee because you need to drink coffee.
The school studies a number of other caffeine effects, including anxiety, sleep disruption, tolerance levels, withdrawal and addiction. Another interesting one is caffeine intoxication, which looks at the potential for caffeine intoxication to cause severe mental distress. It includes the study of the who, what and why of intoxication and its short term and long-term repercussions on human health.
Although the Vanderbilt and John Hopkins' programs have as their focus different aspects of the coffee and health issue, they do have at least three very important features in common: Vanderbilt and John Hopkins are both well-respected Class 1 research universities; both programs appear to be well-funded and long-term; and they are both well-practiced in the art of information dissemination.
The above list of health effects is enough to make any coffee professional shudder. But, as the International Coffee Organization begins a campaign to tout the health benefits of coffee consumption throughout the world, it is vitally important for our own health as well as for the health of the industry that we, as roasters, stay abreast of the on-going research on both the positive and negative effects of coffee and caffeine on health.

Socially Scientific

The social science and economics implications of coffee are so large they are sometimes difficult to grasp, whether we're talking about fair trade and organic programs, or just trying to ensure that those in every step of the coffee creation chain receive as many benefits as possible from creating quality coffee. The benefit of university and other programs that look at the socio-economic side of coffee is that they often look at one topic in a very specific, very forward-looking way to answer questions like, what's out there now, how is it working, and what can we improve on for the future? It also helps to remind us that we do not practice our craft within an information vacuum, and that very serious research institutions are watching and analyzing the economic and social footprints that we leave through the coffee trade.
One of the more interesting of these is the Fair Trade Research Group at Colorado State University (CSU) in Boulder, Colo., and the offshoot, Center for Fair and Alternative Trade Studies. The goal of both programs is to train social scientists in the tools necessary to critically and accurately evaluate emerging alternative market structures. Their ultimate goal is to bolster alternative market participation through a fuller and more realistic accounting of the costs of the existing free-market structure.
This program is of special interest to roasters for a number of reasons: the rising importance of alternative markets in specialty coffee (organic, fairtrade and direct buying); the ability to more accurately evaluate the viability of competing alternative markets; and evaluation of the functioning of alternative markets in meeting stated social goals vs. existing market structures. Along this line, the Fair Trade Research Group at CSU published an interesting study entitled Poverty Alleviation Through Participation in Fair Trade Coffee Networks. The study looked at fair trade's current standards and procedures, explored the inconsistencies, and offered suggestions for future improvements. (You can read the entire article online by visiting the CSU website at http://welcome. colostate.edu and searching by the title).
At Michigan State University in East Lansing, Mich., the Department of Agricultural Economics, along with the USAID, developed surveys and studies that focused on guaranteeing food security for the African country of Rwanda. This project, the Rwanda Food Security Research Project, was designed "to improve the capacity of Rwanda's Ministry of Agriculture to analyze food security, to formulate policies, institutional reforms, investment plans, and management processes that produce food security."
Michigan State studied five issues as they related to Rwandan food security, one of which was a socio-economic look at the coffee sector which focused on the supply side at the household level (termed farmers' decision-making perspective). The goal was to find a way to increase food security through a broad-based, market-oriented sustainable economic growth strategy.
In order to achieve the stated goals, Michigan State designed a farm-level coffee survey based on a study originally conducted in 1991. The survey sampled 1,584 small-hold coffee farmers, asking questions about cultivation, processing, current prices, future prices, their own farming practices and their future expectations. The study identified the largescale failure of Rwandan farmers to employ best practices at all stages of the green coffee growing and processing chain. These failures then resulted in the loss of high-quality coffee due to poor plant maintenance and processing methods. The resultant lower yields and lower prices caused by poor quality further caused many farmers to abandon coffee altogether. This "low yield, low quality, low price" spiral deprived many Rwandan farmers of the cash that comes with a ready export crop, one they were badly in need of.
The final report for this study was compiled, including suggestions, and presented for publication and dissemination in early 2003. It is interesting to note that three years later, the Rwandan coffee sector is in a recovery phase. Rwanda is now recognized throughout the specialty coffee world as a "comer" that has the ability to produce high-quality, distinctive coffees consistently. Some of this growth likely can be attributed to the economic and agricultural surveying and compilation of suggestions undertaken by a university located in the American Midwest.

Food and Farming

For roasters, perhaps the most interesting programs are those that roast coffee on campus and then sell it, in one form or another, to other entities associated with the institution. Currently there are at least two of these types of programs in existence, one at the university level and another run by a community college.
The university-level program is run by Clemson University in Clemson, S.C., within its Food Science program. This program was created and is currently administered by the head of Clemson's Food Sciences Department, Dr. Johnny McGregor, and has been in existence for nearly five years. McGregor is familiar to many of us in the Roaster's Guild as the milk expert that first alerted us to the importance of the then-emerging latte and cappuccino culture to the American dairy farmer at the first Roasters Guild Retreat in Forest Grove, Ore., that took place way back in August 2001.
In McGregor's program, students do everything a wholesale or retail roaster would do in the everyday running of a business. They source all the green coffee, determine roast production schedules, roast, package, set prices and deliver to the student-run cafe, MicroJoe. "It is an attempt to teach students the entire food processing chain, from farm to table," says McGregor.
The comprehensive program identifies interested and talented freshmen and pulls them into a team that is already operating the production, distribution and sales sides of the business. The students are paid and are currently in the process of developing a bonus plan based on profitability and quarterly targets that would pool the bonuses for use as an internal investment pool through a student-controlled grant process. All the while they are taking classes within their food science major.
Every team includes a mix of grad and undergrad students, enabling the students to get "job promotions" as those above them vacate their positions to move on. This allows matriculation and promotion without the usual loss of corporate knowledge that would occur. As McGregor says, "The team approach allows students to take a longer term view of the businesses they are running, whether it be the creamery, the roastery or the retail store."
Currently, the lab that holds the roastery is undergoing renovation, which has forced Ashley Spokowski, the roastery's production manager, to source roasted coffee and to deal with the reduced margins that such a system entails. Spokowski says that being a production manager of a working roastery and creamery is a "great learning experience" that has taught her a "new aspect of food, and the experience of a start-up" as she deals with the positioning of the roaster in its new space.
Meanwhile, Heather Johnson, a senior that held Spokowski's job as production manager last year, is dealing with the build-out of an entirely new retail space to be called the 55 Exchange. Johnson is dealing with architects, framers, dry wallers, electricians and plumbers, all at the ripe old age of 21. However, Johnson admits this job is easier, thanks to her time as a roastery production manager, where she developed profiles and researched coffee-related issues such as organic certification, organic decafs and flavor retention for freshness. "I have seen the whole aspect of the coffee roasting process," she says. "Now I know the language of coffee."
Both women expressed a new-found respect for coffee as a product and for roasting as a process. Johnson is also interested in possibly owning her own retail roastery and bakery someday. She believes that she may pursue that dream as her "second career." No matter their ultimate career goals, these women and their peers will leave Clemson with food science degrees and a multi-year roasting and coffee business experience. No doubt that eventually, some of these students will find their way into our industry helping to raise our knowledge base and helping to further professionalize the craft of roasting coffee.
The second, and in many ways perhaps the most surprising, educational roasting operation, is run out of little Blue Mountain Community College in Pendleton, Ore. No other post-secondary educational institution is more accessible to the ordinary person than their local community college, and the centering of such a program in such an accessible venue is the epitome of information dissemination.
This program, designed and administered by professor Dale Wendt of the Agricultural Department, was originally conceived as a way to help traditional agricultural students, those straight off the farms of their forefathers, find a place in the food processing chain, even if they have lost their place on the farm. In other words, the children of Oregon farmers are using coffee as a way to understand the wider world of food processing, distribution and marketing. Manufacturing coffee (roasting and packaging) has one of the lowest initial capitalization costs of any food manufacturing processes, while at the same time retaining all the complexity, we as professional roasters know and love. These factors make coffee an excellent candidate for what Wendt calls a "learning factory, a place for a hands-in, hands-on learning experience."
Another interesting thing about coffee manufacturing from a learning point of view is that the process is very scalable, according to Wendt, meaning that it is very easy to add capacity and/or capital where it is most needed and where it will realize the quickest return. This helps students understand not just the processing but the business side of manufacturing as well. For example, if the students are experiencing a bottleneck in their packaging, they can easily break down the different steps in their manual packaging operation--from grinding (if needed) to weighing to getting the coffee into the bag to sealing the bag and finally into cases or cartons for distribution. They can easily determine which steps take the longest, or require the most labor, and then seek the tool that can help them to overcome the problem. From there, it is easy to figure out any number of business related issues from payback on capital, to new business possibilities arising from decreased marginal costs and increased manufacturing capacity. In effect these students are running small businesses, and learning from many different disciplines as all small business people must.
Along the way, they are also learning about coffee. Blue Mountain Coffee student and livestock major Damon Long said he was "surprised at how large the coffee industry was" and that he made the classic mistake of "not even thinking much about the amount of labor that goes into the production of coffee."
The Blue Mountain program is associated with another agricultural program: AgrowKnowledge. A program of the National Center for Agriscience and Technology Education (NETEC), a national partnership of community colleges focusing on the food industry, AgrowKnowledge seeks to be a bridge between community colleges in largely agricultural communities; business industry universities with recognized agricultural programs; and food-oriented professional organizations. The goal is to disseminate information, expand career opportunities for students interested in the food sciences and facilitate growth and innovation within the food sciences.
Coffee as an industry, especially specialty coffee, has long been dominated by an ethos of low technology, high rates of manual labor, and often unproven science accepted as fact. Compounding these issues, the craft of roasting specialty coffee has most often been practiced by smaller niche players with relatively low rates of capitalization that were generally isolated from the harder sciences and the changes in technology occurring around them. Programs such as those at Clemson and Blue Mountain Community College, as well as associations such as NETEC and programs such as AgrowKnowledge, can only help roasters and roasteries of all sizes understand emerging food science technology and be a better prepared and motivated workforce.
The coffee industry that many of us entered is changing, for the better. Technological advancements are forcing many of us to rethink old roasting precepts, while a new generation of roasters is quickly gaining the skills that it took many of us years to get the experience to master. The post-secondary education establishment is showing coffee, and especially coffee roasting, a newfound respect based on our economic force and staying power. But with respect comes responsibility: as an industry, it's the opportune time to reach out and partner with local education establishments and culinary schools to help bridge the gap between theory and practice. And perhaps to learn a thing or two about coffee along the way.

Tuesday, May 27, 2014

A Trip Into the Future of Packaging (Wired For Roast 3)

A Trip Into the Future of Packaging
Tastes As Great As It Smells Coffee
(As reported in TechnoPack News)


In late 2006, a new coffee is coming to the coffee drinking consumer: Grand Bouquet Coffee. Grand Bouquet delivers the discerning coffee consumer a gourmet experience at a cut-rate price with coffee that "tastes as great as it smells!" According to Joe Raymond, marketing director of Great Scents Brands, Grand Bouquet Coffee "is putting a new spin on gourmet coffee through its unique coffee scented packaging." Mr. Raymond goes on to state that the packaging actually enhances and reinforces the pleasantness of the coffee by stimulating the olfactory receptors in the brain even while the great coffee smell of the package entices consumers to take a bag home. "This allows us to buy less expensive coffee and, through aromatic enhancement, turn it into gourmet grade coffee, truly magic," says Raymond. Selling at $4.99 for a 12-ounce bag, Grand Bouquet is priced well below other gourmet coffee brands currently offered in grocery stores.
THE PRECEDING PACKAGING PRODUCT is a bit of coffee science fiction. But, as with most sci-fi stories, the future that is portrayed is not far away. Computers that send messages, diagnose and heal illnesses, even think for themselves--these were all once only products of a sci-fi writer's imagination. The same is happening with coffee packaging: from packages that enhance the scent of coffee, heat themselves or keep tabs on their contents--if someone can think it up, then there is a good chance we'll see it on the shelves at some point in the future.
If, five or 10 years ago, you'd taken a poll of coffee industry professionals about the packaging progress they hoped and expected to see in the future, their list of priorities probably would have looked something like this: product quality and freshness, sustainable materials and better marketing options.
Today, the future of packaging is here, and it doesn't look at all like what we expected. While we sit around debating the freshness and environmental impacts of bags versus cans, the rest of the world has moved forward on the marketing front. Just in the last few years, marketing products like inexpensive professional quality label printers and new packaging finishes have made their way into the industry. And, now, a new future of packaging has arrived: Smart Packaging. This movement, for coffee and other industries, is here to stay. And it's large--it has trade magazines (The Smart Packaging Journal); white papers, and conferences (Intelligent & Smart Packaging USA).
While the terms smart and intelligent packaging might conjure up images of gee-whiz packages that freeze, open, cook themselves or even whisper to you from the shelf, it is really much less exciting than that. Smart packaging is very simply a package designed to do more than to convey or hold a product. To quote Packaging Materials & Technologies, a leading consultancy for the packaging industry, "Forget about all those numerous definitions-- active, diagnostic, intelligent, smart, functional, enhancement--to describe smart packaging. Just stick to "smart" and figure it's all one big continuum of functionality. In fact, think of smart as meaning clever, neat or "wow" and you'll get the picture."
Today, many specialty coffee roasters subscribe to the theory and some of the concepts behind smart packaging, many without even knowing it. Unusual or stunning graphics, packages in custom shapes and sizes, and even freshness valves, can all easily fall under the rubric of smart packaging. But, what of the truly gee-whiz, geeky or techno stuff in packaging today? We are now entering a period where packaging is increasingly used to monitor freshness, track distribution, heat and cool products and even communicate with the consumer. In other words, packaging and packaging materials are becoming more communicative, interactive and functional. In many cases the packaging material is being developed and manufactured to do jobs that are currently done by hand, or left undone.
As markets become increasingly global, the packaging industry is quickly responding to the challenges of long-term storage, long-distance shipping and cross cultural differences. Currently food and beverage packaging makes up the lion's share of the industry; nearly 60 percent of the packaging industry is for food and beverage, including coffee. According to NanoMarkets, a technology research firm, smart packaging for food and beverage will increase from the current $4.4 billion to $14.1 billion by the year 2013. Smart packaging includes such technologies as radio frequency identification (RFID), olfaction packaging, self-adjusting freshness indicators and self-heating packaging that may all have some level of relevancy for the coffee industry.

Smart and Intelligent

Smart and intelligent packaging falls into two distinct categories. The first is those packages that are made intelligent through the attachment of sensors or RFID devices to an existing package, such as those used in traceability.
The second category is defined as packages made smart through engineering of the packaging whether by mechanical, chemical, electronic or electrical means and active interaction of the product and the package itself. That is, the package must have some desired effect on the product or the product must have some desired effect on the package. For the specialty coffee industry three types of these technologies--olfactory packaging, interactive freshness indicators and self-heating packaging--are already being used, with the potential for many more on the way.

Smells Good, Tastes Great?

Scientists have long known of the positive psychological effects of pleasing scents to the moods of humans. And probably marketing people have been trying to manipulate them for just as long. The sense of smell is the only sense that is processed directly in the limbic lobe, the emotional center, of the brain, making it perhaps the most valuable sense to marketers as it bypasses the logical portion of the brain. We are all familiar with the perfume pages in fashion magazines, scratch and sniff scents and other such marketing material, but how about the smell of fresh-roasted/ground coffee emanating from barrier packaging on the store shelves?
That barrier has now been crossed. A company called ScentSational Technologies creates coffee-scented packaging by introducing FDA-approved food-grade flavors and fragrances directly into the manufacture of the packaging materials; these are the same flavors and fragrances that are currently used in flavored coffee. The scent is embedded into the material during manufacture, thus a bag manufactured for coffee would smell like coffee before it was ever near a bean.
The implications of this are huge, of course. Theoretically the process could be very discriminating, choosing only those coffee flavors associated with freshness and even those indicative of certain origins. Maintaining and enhancing say the blueberry in a Harrar, or the lemon of a great Yirgacheffe or any other distinct aromatic profile desired, including fresh ground coffee. Or a coffee may smell as fresh as when it was first bagged as the packaging transfers the fresh coffee smell to the coffee itself. This type of technology would have no bearing on products pulled for spoilage or safety reasons, but could increase the shelf life of products such as coffee, which is pulled off shelves for scent and flavor degradation. Olfaction packaging also may have applications in the flavored coffee market, flavoring the coffee through the bag instead of flavoring the bean directly.
In addition, this technology is currently being used for beverage packaging--the aroma of fresh coffee is built into coffee lids used for carryout, as well as potentially into the ready-to-drink cold drinks. Envision drinking a cup of crappy convenience store coffee that smells so fresh you can taste the quality, and you get the idea.
According to Steven Landau, chief technology officer for ScentSational Technologies, this type of packaging will grow. "Based on consumer research and shelf-life testing, olfaction packaging will have widespread appeal and long-lasting applications for food packaging," he says. "It makes products last longer and gives consumers the sensibility of freshness."
Olfaction packaging technology, not unlike organic acid manipulation (Wired For Roast, Roast magazine, March/April 2006), may have very serious long term implications for the specialty coffee industry, and especially for roasters and growers. Although no doubt there are good uses that can come from this technology, if not managed well, this technology could be used to hide old, faded coffees, add elements to coffee that were not present in the first place, and in general to deceive consumers as to the freshness, aroma or origins of the coffees they are purchasing and drinking.

Freshness Counts

Another area of interest for coffee roasters is the possibility of more accurate freshness indicators for specialty coffee. Currently, it is nearly impossible for a consumer to know whether a coffee is beyond its freshness threshold unless they buy it directly out of the cooling bin of the local roaster. Even if the industry had an agreed-upon program (we don't) for date stamping and/or a use by freshness threshold, it would hardly be accurate due to the vast variances in the way roasters currently package coffee. With whole-bean coffee packaging alone the packaging permutations are nearly incalculable; some roasters de-gas, some don't; some valve pack, some don't; some vacuum pack, some don't; some nitrogen flush, some don't; some do all the above and some do none and on and on it goes. So, even if the industry could agree on a standard, it would hardly be an accurate measure of coffee that was beyond a selling point for consumers. Enter Self- Adjusting Use By/Sell By Dates.
This active smart packaging uses existing technology to sense the fall or rise of single or multiple chemical indicators to estimate when a coffee should be consumed by to ensure a pre-determined level of freshness; if there is a change in the rate of product degradation, the use-by date physically changes to reflect the new reality, guaranteeing that the consumer has an accurate date to make a determination of freshness based on their own coffee consumption patterns.
This technology is already being used to sense the ripeness of packaged pears through the sensing of the level of aroma. This smart package, called RipeSense, changes the sensor on the face of the packaging to indicate the true level of ripeness. A related technology is being used in consumer dairy packaging to prove freshness and reduce unnecessary waste in plastic milk cartons.
To sum, it could soon be possible to have an accurate useby / freshness date based on the science of measurable chemical parameters; a date that consumers can easily read and understand and that is accurate. The measuring instrument will be embedded in the packaging material during the manufacturing process. Thus, the package itself becomes a more accurate sensor of freshness than any measure or scheme currently in use. This type of technology for coffee has a strong potential market on the specialty side, as it is specialty roasters who have the most to gain through better and more accurate freshness monitoring.
As great as more accurate freshness parameters for coffee would be, it is unlikely that the specialty coffee industry as a whole will adopt these technologies and conceive the measures that would lead to widespread adoption. Perhaps a few intrepid specialty roasters that are truly interested in freshness will utilize this new technology and move forward alone. These companies could hopefully gain an edge in the market while proving to the consumer that freshness is a serious issue for great tasting coffee. Better freshness regimes can also help farmers, as old coffee is pulled from shelves and fresher coffee is offered in its place. The day specialty coffee is truly treated as a perishable agricultural product will be a great one indeed for growers, roasters and consumers alike. Perhaps Interactive Freshness Indicators can help bring the specialty coffee industry to this new dawning.

Too Hot to Handle?

And now we come to the final, and perhaps the most unexpected packaging development: self-heating packaging. On November 7, 2004, at the Pack Expo trade show in Chicago, Ill., a little known company, OnTech Delaware, debuted the first North American developed and manufactured self-heating container. The container was designed and marketed with the ready-to-drink tea, cocoa, soups and coffee markets in mind. The product soon attracted the attention of Beverage Partners LLC, a company working with the famous chef and restaurateur, Wolfgang Puck. By January 2005, Wolfgang Puck's lattes were headed to American store shelves to battle with other more traditional forms of lattes.
So, how does it work? The self-heating can utilizes a chemical reaction of calcium oxide CaO (quicklime) and water to heat the product. The CaO H2O mixture is isolated from the coffee by an inner liner, and the insulated outer can keeps the already liquefied product warm without burning the drinker. All consumers need to do is turn the can upside down, pop the bottom and watch the little indicator button to know when it's hot enough to drink. Clever indeed, but like a teleportation project gone terribly wrong, sometimes things don't go as planned.
In the spring of 2006, a short year after coming to market, reports began to surface of the lattes getting too hot, leaking chemicals into the coffee, and even exploding. In April of 2006, the product was pulled from store shelves. Currently the FDA is looking into the complaints and all involved parties are no doubt busy preparing for court (if not over consumer actions, then certainly against one another).
The lesson here is that not all emerging technologies are ready for market, and in some cases, perhaps never should have come to market at all. At any rate, be sure that the American coffee consumer has not seen the last of self-heating smart packages. smart_label_schematic

Tracing Paper

Radio frequency identifying devices (RFID), which allow the identification of a product through radio frequencies, come in various forms, including: smart seals, key fobs, and condition monitoring tags, in-transition condition monitors and time and temperature indicators. Some RFIDs are active, automatically relaying information such as a change in condition, or an out of limits situation to a central monitoring system. Others are passive and draw their energy as they pass under or through a system such as a hand-held reader or conveyor mounted apparatus. Although many types of RFID hold relevancy for the specialty coffee industry, perhaps the two with the most potential for coffee roasters are real time locator systems (RTLS) and smart active labels (SALs). laminated_energy_cell
Currently, RTLS are matchbox-sized tags with small batteries that can be easily attached to any container. These devices send a signal that is picked up by a network which records and logs the time and location. Such a system could be used in the specialty coffee industry to track an estate green from source through a broker to a roaster then onto a store shelf. It could also very easily be utilized as part of a product verification regime, such as those being sought for organics, or to ensure the receipt of current crop coffees. Additionally with a little imagination these types of systems could also have value to interested consumers. One thing is for sure: RTLS should have a place in the specialty coffee industry as growers, brokers and roasters seek out more and better market differentiation through verification.
SALs are the next generation of RFIDs and an improvement over the older RTLS. SAL systems are thin labels that contain an integrated circuit and a power source. The system must also have a receiver (often handheld) to read the data and some sort of a data collection and retaining system (generally a PC- or Internet based program) to enable an interested party to accumulate, track and process the data. The flexibility offered in SAL systems is much greater than that currently offered in RTLS-based tracking and traceability programs.
Active RFIDs including both RTLS and SAL signals can currently be read by a wide, and ever more widening, group of receivers. Among the products able to be used as RFID receivers and/or relays are: WiFi, Bluetooth, GPS, Cell Phone, Infrared, GSM, GPRS and Passive RFID. This ever-increasing circle of available and, in many cases inexpensive, receiving devices make these emerging packaging technologies perfect for reporting, tracking and verification programs.
Although these systems are already in use in the market, they are currently somewhat cost-prohibitive. According to Baruch Levanon, chairman of the Smart Active Labels Consortium (SAL-C), a non-profit trade oriented interest group, "the goal is an item-level disposable tag that can be tailored not only for function but for size and space requirements ensuring low-cost, real-time data." Currently SALs cost a few dollars per unit. However, Levanon says, "When in the future, we should get to a fully-printed label, the cost will drop to a few cents." Utilizing energy cells made from inks, some SAL labels can be laminated not unlike conventional labels. With printed batteries, microelectronic circuitry and printed antennas these labels can be less than 1mm thick and should be able to be produced by traditional printing practices, making the technology cheaper and helping to lead to more widespread use of such devices. FlowDiagram
So how do, or can, RFID packaging technologies affect the specialty coffee industry? Currently some RFID tracking is being done at origin, and no doubt this practice will become more common as traceability becomes an ever larger issue for the industry. There is simply no conceivable reason why this technology, as costs drop, should not also eventually be adopted by specialty brokers and roasters for verification of origin, organic transparency, handling and the time tracking of shipments. Furthermore RFID technology coupled with PC and/or Internet based roast data-logging systems could conceivably reduce the administrative costs of handling organic, fair-trade and other certified coffees for growers, brokers and roasters alike. A system such as the Organic Process Evaluation Network (OPEN) system outlined in the OPEN graphic (page 69) would add a new level of integrity. Such a system would be more secure; reducing the chance of any company or individual gaming the certification system. By reducing the likelihood of consumer fraud while allowing the consumer to access the verification process the specialty coffee industry would be taking a giant proactive leap forward.
Through the use of existing, albeit new, systems and devices such as SALs, RTLS, active RFID capable devices, PC-based control systems and the Internet, roasters could turn a production-oriented system into a marketing tool and hopefully expand the market for specialty coffee through the trust engendered by a fool-proof system that allows verification at the consumer level. With smart packaging, the package becomes the source of conveyance, marketing and active verification of certified products direct to the consumer.

The Future Is Now

RFID, SAL, olfaction packaging, interactive indicators: all of these smart technologies seem to be a long way from where most specialty coffee roasters are today. And yet it was not so long ago that roasters were debating the very efficacy of bean probes and digital controllers. And for the world of the working roaster, some of these technologies hold promise (self-adjusting use/by freshness indicators, RFID), while others may offer grave threat (olfaction packaging). Some may help us connect more directly with consumers and expand our businesses and our industry, while some may threaten the very foundation of our operational paradigms, our businesses and perhaps our industry itself. Whatever develops from these technologies, it is vitally important that those roasters in the specialty end of the industry pay very close attention to the developments occurring in the packaging industry.
Perhaps it will not be long before we see a press release like this:
The Global Specialty Coffee Association announces its new Guaranteed Freshness program for consumer packaging. The program will ensure the freshness of pre-packaged whole-bean coffee through a sophisticated chemical-sensing unit manufactured into the packaging material. Interested coffee companies need only buy the packaging material, pre-formed or roll stock, to participate. This is a licensed technology and is the result of years of collaboration between the packaging industry, food scientists specializing in the chemical make-up of coffee, and other interested coffee professionals working through the GSA. Licensing fees will be used by the association to fund further coffee-oriented research and for marketing the Guaranteed Freshness program.
We can only look into the future, and hope.

Further Reading on Smart Packaging Technologies

Packaging Digest
www.packagingdigest.com
Smart Active Labels Consortium SAL-C
www.sal-c.org
IDTechEx, packaging research and analysis
www.idtechex.com
Discovery Channel Ripesense report
www.exn.ca/dailyplanet/view
PackWire, news on packaging technologies
www.PackWire.com
School of Packaging at Michigan State University
packaging.msu.edu
Self-heating container video
www.ontech.com/video