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Advanced Workshop For Master Roasters DakLak June2024
Advanced Workshop For Master Roasters DakLak June2024
With emphasis on roast profiling and consistency of roasting and post-roasting processes
Manuel Diaz
ONA Consulting
Hanoi, Vietnam 2024
Objectives
Contents:
b. Modulation of coffee flavor based on processing methods. How to adjust roast profiles
according to the coffee processing method: washed, honeys and naturals and new
infused coffees, and long fermentation processes.
c. Basic blending theory. Sensory and economic principles in the preparation of blends
(modulation and balance of coffee flavors; consistency in flavor profiles; cutting down
costs). Exercises for making mixtures with different types of beans and roast profiles.
DAY 1
INTRODUCTION. The coffee value chain and the role of the roasting industry. Importance of the
professionalization of the roasting machinery operator.
Exercise 1: Physical inspection of a coffee sample before roasting (odor, color, shape, size,
moisture content and drying quality, bulk density, and defects)
2. Sample roasting standards and protocols. Sample preparation protocol for sensory
evaluation.
a. Reference indicators:
I. Weather
II. Color
III. Temperature
IV. Decrease
Exercise 2: Roasting different types of green coffee samples. Use the roast log to determine the
optimal degree of roasting for different types of green beans.
• High and low relative density samples
• High and low moisture content samples
• Heterogeneous and homogeneous samples (size, density, process)
• Physical and chemical transformations of coffee during the roasting process. Main
phases of the roasting process; key points to identify the development of roasting and
control parameters (time, temperature, color, weight loss, fragility, elongation).
• System and control mechanisms and security elements of the roasting machines.
DAY 2
b. Main technologies and roasting systems; forms of heat transfer; Advantages and
disadvantages of each one.
I. Free Hot Air Flow Roasters (Fluid Bed and Jet)
II. Drum roasters (direct and indirect heat)
III. Drum roasters with forced hot air flow
IV. Tunnel and continuous flow roasters
2. Complex physical and chemical transformations during the coffee roasting process.
a. Main physical and chemical changes of the coffee bean in each phase of the roasting
process;
I. Hydrolysis and dehydration
II. Millard reactions, color changes, initial cracking
III. Strecker reactions, first crack
IV. Caramelization, volatile and heavy weight byproducts
V. Pyrolysis
Exercise 3: Roasting a load of green coffee in an industrial roaster until the start of the 2nd
crack. Withdraw samples every minute from the top of the 1st crack until the end of
roasting. Use a roasting log and/or its graphic expression to identify the main stages
and critical points of roasting (color, aromas, development of the roast according to
the time and temperature reached)
Exercise 4: physical and sensory evaluation of the roasted samples applying the physical and
sensory standards of roasted coffee. Identify the uses of different roast levels.
3. Deviations in the roasting process and main roasting defects. Quality standards and physical
inspection of the roasted bean.
a. Discriminative sensory evaluation of the quality of roasted coffee.
b. Control and consistency in the handling of roasting machines.
c. Use of logs, formats and quality control indicators for roasters.
4. Sensory roasting curves and roasting profiles: dynamics of the formation of acidity, aromas,
sweetness and body at different points in the roasting process. Predominance of chemical
reaction types, typical flavor precursors, and potency thresholds and temperatures.
5. Most common roast levels in the coffee market. Application exercises of degrees of roasting
according to color, roasting time, outlet temperature, loss and cup profile (for different
types of coffee beverages). Identification of the roasting parameters for each level of
roasting (color, roasting time, outlet temperature, shrinkage and cup profile).
Exercise 7: Roasting samples at different roast levels (adjust roast profile and evaluate time,
final temperature, weight loss, brittleness)
• Scandinavian-type light roast for espresso, Agtron 75-80, 192-193 °C, 12% shrinkage,
6'00” minutes
• Specialty-type light roasting for pour-over, Agtron 65-70, 195-198 °C, 13% shrinkage,
7'00” minutes
• Light medium roast specialty type for dripper, Agtron 60-65, 206-208 °C, 14% shrinkage,
9'30” minutes
• Medium slow roasting for dripper, Agtron 50-55, 214 °C, 16% shrinkage, 10'30” minutes
• Medium dark slow roast for espresso, Agtron 45-50, 221 °C, 18% shrinkage, 12'30”
minutes
• Italian type dark roast (very slow) for espresso, Agtron 40-45, 230 °C, 20% shrinkage,
14'30” minutes
DAY 3
• Exercise 8: Scaling 3 optimal roast profiles (from sample roaster to industrial roaster):
Exercise 9: Conformity evaluation of the finished product according to physical and sensory
standards. Evaluation of consistency and precision in roasting processes.
Exercise 10: Prepare the following blends with the available coffees (document the roasting
protocol: profile, initial and final temperature, time, weight loss, fragility):
• Blend for Italian type espresso. Roast with abundant body. Caramel and chocolate
flavor, intense sweetness, abundant body, moderate acidity
• Mix for French press (Very sweet roast). Balanced flavor, intense sweet, medium body,
moderate acidity
• Blend for pour-over (light roast with intense aroma and bright acidity). Intense aromas,
bright acidity, mild flavor, light body.
Day 4
Post-roasting processes
• Cooling down standards and innovations
• Degassing process and packaging.
I. The role of CO2 and degassing best practices
II. The role of positive pressures
III. Degassing whole beans or ground roast coffee (depending on roast products)
• Packaging materials and standards
• Degassing valve types and performance
Exercise 11. Grinding, analyzing particle size distribution and cupping the same coffee with the
same roast profile (accurate protocol to control preheating, roasting, and cooling)
• 0 hr of degassing
• 1 day degassing and vacuum packing
• 5 days of degassing in standard roast coffee bag and 1-way degassing valve
• 15 days of degassing with high positive pressure valve and double packaging barrier
Exercise 12. Cupping coffees with 2, 8, 16 and 32 minutes of cooling down, immediate packed
in the same bags and valves for 24 hr for degassing.
Scope:
• Advanced level coffee roasting, theoretical as well as intense practical components;
• Practical exercises for the evaluation of green bean samples;
• Sample roasting practice in small groups;
• Industrial roasting in small groups;
• Use of roasting software and measuring instruments;
• Advanced sensory evaluation of results (sensory profile and performance according to
extraction method).
Deliverables:
• PPT presentation
• Roasting profile files
Addressee:
Master roasters, roasting machine operators and coffee professionals with advanced practical
experience. Maximum of 20 participants (4 sample roasters, 4 roasting machines, 4 cupping
tables)
Requirements:
• Roasting machines: a sample roaster (capacity 100-250 g) and an industrial roaster
(capacity 1 kg minimum/10 kg maximum) for every 5-6 students.
• Instruments: portable infrared temperature meter (fast reading; at least 0.5 seconds),
moisture content meter and green bean density meter; digital roast coffee
refractometer; laser particle size analyzer for ground coffee; Precision scales (1000g
capacity and 0.1g precision), high resolution microscope (at least X400), stopwatchs.
• Professional grinders (1 per every 10 students)
• Different types and origins of green coffee (very well classified). The volume depends on
the capacity of the industrial roaster. Estimate 80% of the maximum roaster load as the
ideal load size; consider at least 4 loads per type of bean.
• Best 5 roasted coffee products and 3 main sellers in supermarkets from the main
roasters in the region or country.
• Basic cupping equipment (cups, pitchers, spoons, spittoons, aprons, etc.)
• Whiteboard for erasable markers (water-based) and 4 colored markers (black, blue, red
and green).
Expected impact:
• Participants will learn how to perform a rigorous physical inspection of the green bean,
how to manage roast software and consistently apply roast profiles, as well as perform
physical and sensory evaluation of the roasted bean.
• Participants will have the ability to control roasting processes and identify major roast
deviations such as scorching, tipping, and facing, as well as design advanced profiles and
roast coffee blends, and to improve roasting processes.
• Participants will control post-roasting processes to enhance roast coffee performance
during grinding and extraction.