Disclosed herein are embodiments of an energy recovery system for a freeze-drying system. In some embodiments, the freeze-drying system includes a freeze dryer chamber having one or more shelves disposed therein; a refrigeration system comprising a refrigerant condenser; a heat exchanger; a first fluid line to thermally couple the refrigerant condenser to the heat exchanger; and a second fluid line to thermally couple the one or more shelves to the heat exchanger.

The present invention provides a method for the manufacture of a freeze-dried coffee powder, the method comprising: providing a coffee extract having from 40 wt % to 55 wt % solids; adding gas to the coffee extract in an amount of from 1 NL/kg to 5 NL/kg of coffee extract, to provide a gas-containing coffee extract at above atmospheric pressure; depressurising the gas-containing coffee extract to form a foamed coffee extract; cooling the foamed coffee extract to below 40 C. without shear, or with low shear, to form a frozen coffee extract, grinding the frozen coffee extract to a powder; and drying the powder, wherein the step of cooling the foamed coffee extract to below 40 C. comprises: (i) cooling the foamed coffee extract to a first temperature; (ii) cooling the foamed coffee extract from the first temperature to a second temperature lower than the first temperature; and (iii) cooling the foamed coffee extract from the second temperature to below 40 C., wherein the first temperature is 1 C. above a freezing point of the foamed coffee extract and wherein the second temperature is 3 C. below the freezing point, wherein step (ii) has a duration of from 5 to 90 minutes, preferably 10 to 60 minutes.

The present invention provides a method for the manufacture of a freeze-dried coffee powder, the method comprising: providing a coffee extract having from 40 wt % to 55 wt % solids; adding gas to the coffee extract in an amount of from 1 NL/kg to 5 NL/kg of coffee extract, to provide a gas-containing coffee extract at above atmospheric pressure; depressurising the gas-containing coffee extract to form a foamed coffee extract; cooling the foamed coffee extract to below 40 C. without shear, or with low shear, to form a frozen coffee extract, grinding the frozen coffee extract to a powder; and drying the powder, wherein the step of cooling the foamed coffee extract to below 40 C. comprises: (i) cooling the foamed coffee extract to a first temperature; (ii) cooling the foamed coffee extract from the first temperature to a second temperature lower than the first temperature; and (iii) cooling the foamed coffee extract from the second temperature to below 40 C., wherein the first temperature is 1 C. above a freezing point of the foamed coffee extract and wherein the second temperature is 3 C. below the freezing point, wherein step (ii) has a duration of from 5 to 90 minutes, preferably 10 to 60 minutes.

A concentrated coffee extract powder (instant coffee) and a system for producing the same are disclosed which includes: selecting and preparing coffee beans by a predetermined quality guideline; receiving a coffee extract by inputting the coffee beans into a high-volume coffee brewing machine a high-volume coffee brewing machine having a plurality of percolation tanks whose fluid inter-communication is controlled by a a Boolen logic performed by a proportional integral derivative controller (PIDC) after receiving time, temperature, and pressure data from the plurality of percolation tanks so that the coffee extract is qualitatively constant in each of said plurality of percolation tanks; freezing the coffee extract mixed with the probiotics in molds using an individual quick freezer (IQF) to obtain frozen coffee extract blocks; and vacuum freezing the frozen coffee extract blocks using a convection current vacuum freeze drying apparatus.

A concentrated coffee extract powder (instant coffee) and a system for producing the same are disclosed which includes: selecting and preparing coffee beans by a predetermined quality guideline; receiving a coffee extract by inputting the coffee beans into a high-volume coffee brewing machine a high-volume coffee brewing machine having a plurality of percolation tanks whose fluid inter-communication is controlled by a a Boolen logic performed by a proportional integral derivative controller (PIDC) after receiving time, temperature, and pressure data from the plurality of percolation tanks so that the coffee extract is qualitatively constant in each of said plurality of percolation tanks; freezing the coffee extract mixed with the probiotics in molds using an individual quick freezer (IQF) to obtain frozen coffee extract blocks; and vacuum freezing the frozen coffee extract blocks using a convection current vacuum freeze drying apparatus.

Disclosed herein are embodiments of an energy recovery system for a freeze-drying system. In some embodiments, the freeze-drying system includes a freeze dryer chamber having one or more shelves disposed therein; a refrigeration system comprising a refrigerant condenser; a heat exchanger; a first fluid line to thermally couple the refrigerant condenser to the heat exchanger; and a second fluid line to thermally couple the one or more shelves to the heat exchanger.

Disclosed herein are embodiments of an energy recovery system for a freeze-drying system. In some embodiments, the freeze-drying system includes a freeze dryer chamber having one or more shelves disposed therein; a refrigeration system comprising a refrigerant condenser; a heat exchanger; a first fluid line to thermally couple the refrigerant condenser to the heat exchanger; and a second fluid line to thermally couple the one or more shelves to the heat exchanger.

The present invention relates to a method of producing a freeze dried soluble coffee powder which produces foam when dissolved in water. The method involves partly melting the surface of a granulated frozen coffee extract and mixing it with a porous spray dried coffee powder whereby the porous spray dried powder particles stick to the surface of the granulated frozen coffee extract particles, and freeze drying the particles.

The present invention relates to a method of producing a freeze dried soluble coffee powder which produces foam when dissolved in water. The method involves partly melting the surface of a granulated frozen coffee extract and mixing it with a porous spray dried coffee powder whereby the porous spray dried powder particles stick to the surface of the granulated frozen coffee extract particles, and freeze drying the particles.

Methods and/or processes for obtaining coffee extracts and/or processing coffee beans. In certain embodiments, improved methods and/or processes for producing desirable and usable extracts from coffee beans which can be used for instant coffee type powders or liquids, for example. In certain other embodiments, improved coffee extraction techniques which permit or allow retainment or capture of desirable levels of aroma products and/or bio-actives from coffee beans.