All About Coffee by William H. Ukers (best new books to read .TXT) π
CHAPTER II
HISTORY OF COFFEE PROPAGATION
A brief account of the cultivation of the coffee plant in the Old World, and of its introduction into the New--A romantic coffee adventure Page 5
CHAPTER III
EARLY HISTORY OF COFFEE DRINKING
Coffee in the Near East in the early centuries--Stories of its origin--Discovery by physicians and adoption by the Church--Its spread through Arabia, Persia, and Turkey--Persecutions and Intolerances--Early coffee manners and customs Page 11
CHAPTER IV
INTRODUCTION OF COFFEE INTO WESTERN EUROPE
When the three great temperance beverages, cocoa, tea, and coffee, came to Europe--Coffee first mentioned by Rauwolf in 1582--Early days of coffee in Italy--How Pope Clement VIII baptized it and made it a truly Christian beverage--The first Europe
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General view of the roasting room of the Jewel Tea Co., Hoboken, N.J. The equipment consists of twelve Jubilee gas machines in four groups; each group having a smoke-suction fan, and a drag conveyor over the three feed hoppers. To the left is a line of flexible-arm cooler cars.
For many years the regular factory machines have been of a size suitable for roasting two bags of coffee at a time; but roasters of larger size have recently come into considerable use.
Plants treating from fifty to a hundred and fifty bags per day are the most common; but the daily capacity runs up to a thousand bags or more. The minimum cost of equipping a plant is somewhere between five thousand dollars and ten thousand dollars. The individual machines are of standard construction; but the arrangement in a particular building, especially for the larger plants, is worked out with great care and with numerous special features, so that the goods can be handled from start to finish with minimum expense for floor space, labor, power, etc.
The practical coffee roaster locates his roasting room in the top floor of his factory building, where light and ventilation are generally best. He usually has a large skylight in the roof, directly over the roasting equipment. In addition to the advantage as regards good light and the convenient discharge of smoke, steam, and odors, through the roof, the top-story location makes it possible to send the roasted coffee by gravity through the various bins which may be needed in connection with subsequent operations, such as grinding, and for temporary storage before the final packaging and shipping.
Wholesale Coffee-Roasting Machinery
The indispensable coffee operations are roasting and cooling; and in practically all United States plants the cooling is followed by "stoning". This is an air-suction operation that effects, aided by gravity, the removal of any stones or other hard material that would damage the grinding mill. The best commercial cleaning and grading of the green coffee has usually left in every bag a few small stones. These can be got rid of better after the coffee is roasted; because it is then not only lighter, but more bulky.
Besides these three operations of roasting, cooling, and stoning, the plant may have machinery for treating the coffee both before it is roasted and after it leaves the stoner.
A SIXTEEN-CYLINDER COAL ROASTING PLANT IN A NEW YORK FACTORY
A SIXTEEN-CYLINDER COAL ROASTING PLANT IN A NEW YORK FACTORY
This is a view of the roasting room of B. Fischer & Co. and shows a battery of Burns coal roasters
Treatment of the green coffee in roasting establishments is of less importance now than in years gone by; first, because most coffees now come to market more perfectly graded and cleaned than formerly; and second, because the whole-bean appearance of the coffee has become of less account, as wholesale grinding operations have increased. Nevertheless, many plants consider it highly important to have a separator for grading the coffee closely as regards the size of the beansβand particularly for the separation of round beans, or "peaberry"βas well as milling machinery for making the coffee as clean as possible before it is roasted. One green coffee operation that has lost none of its old-time importance, but on the contrary is more needed as the plants increase in size, is the mixing of different varieties of coffeeβin proportions that have been decided on by sample testsβso as to get a uniform blend.
The mixer does not blend the various coffees any more surely than a good roaster cylinder will do it, but treats batches of much larger size. This means saving a great amount of labor that would be necessary for putting the desired quantity of component coffees into each individual roaster.
A proper installation of green coffee machinery requires various bins of ample capacity, and bucket elevators by which the coffee can be sent without manual labor from one operation to another. In modern plants, all the bins and elevators are constructed of metal. The separator, with its bins and elevator, may be installed independently of the rest of the plant, the graded coffee being all bagged up again and treated as new raw stockβsome of it to be held for later use, or perhaps sold again unroasted. The milling machine and the mixer, however, are usually so placed and connected that the coffee can be sent from one to the other, and to the roaster feed hoppers, without any manual labor.
When the roaster sells his product in package form ready for the consumer, he will have a packaging department in which are grinding, weighing, labeling, and packing machines and equipment. In some of the more progressive plants, particularly in the United States, all the packing units are incorporated in one machine, so that the different steps in the work are carried on automatically and in one continuous operation.
Green-Coffee-Mixer Connections
To operate at full capacity, without using the story above as well as below the mixer, requires a bucket elevator and three bins, each holding a full mixing batch. The above diagram explains this setting. The mixed coffee in the discharge bin is either drawn out into bags or sent by an elevator to a milling machine or direct to the coffee roasters. A batch ready for mixing can always be accumulated in the feed bin while the previous batch is being mixed or discharged.
The fan is usually hung to the ceiling over the mixer as indicated, and connected to the suction box by a 1-in. round pipe. The fan outlet can be carried directly out-of-doors; but the dusty discharge is objectionable in most installations, and this pipe is usually carried to a dust collector from the top of which the roof outlet is connected.
The efficient roaster-executive equips his entire plant with approved labor-saving devices. In the better establishments, the coffee is carried along by mechanical conveyors through all the operations from the first cleaning machine to the final packaging.
Separating
As already mentioned, a machine frequently found in wholesale plants is the separator, or grader. This apparatus, which is the same in principle in all countries, but varies in size and form according to local requirements, consists of a series of perforated screens. The perforations differ in size; and as the coffee is shaken on them, the small beans drop through the holes, the larger ones passing across the screen and dropping into a receptacle or chute ready for the next operation. The screens are made to grade the beans into large and small peaberry; large, medium, and small flat beans; brokens; and other commercial sizes. The average separator will grade fifteen to twenty bags of coffee in an hour.
Green-coffee-milling machine having a capacity of forty bags of green coffee per hour; with sifter, feed-pipe suction, and a final separate suction at the discharge hopper
Green-coffee separator without fan; with feed elevator, discharge chutes, and motor drive. View of right-hand side and feed end
GREEN-COFFEE SEPARATING AND MILLING MACHINES
Milling
Milling machines, for cleaning the green coffee, operate on practically the same principle the world over, varying in capacity and details of construction. A popular type used in the United States has two metal cylinders, one set within the other, and revolving in opposite directions. The inner cylinder is ribbed with flanges, and the outer one is lined with wire cloth. As these cylinders revolve, the beans pass between them rubbing against themselves and the rough sides of the cylinders. This action serves to remove dirt and other foreign matter that may be clinging to the beans, and also gives them an attractive polish. An exhaust fan sucks away the dirt milled off in the process. This type of machine will mill about forty bags of green coffee in an hour.
Mixing or Blending Green Coffee
Most roasters blend the different types of coffee while green. Some blend them after they have been roasted separately. When blended before roasting, the coffees are mixed by a machine built especially for that purpose. The mixing machine in general use in all countries consists of a large metal cylinder which, in wholesale operations, is revolved by the factory's general power plant or by a separate motor. The cylinder is equipped on the inside with sets of reverse-screw mixing flanges that tumble the beans around until they are thoroughly blended; and there is usually a fan attachment to remove dust. This operation serves also to smooth down and to polish the surfaces of the beans, which adds to the style of the coffee when roasted. The average blending machine will mix from ten to twenty bags of coffee at a time. The actual mixing requires less than five minutes, but a longer period is needed for feeding and discharging. This is the last of the so-called "green-coffee operations". The next step is roasting.
Roasting by Coal, Coke, Gas, and Electricity
Coffee is roasted commercially in cylinder or ball receptacles revolving in heated chambers, the degree of heat reaching about 420Β° Fahr. The cylinder type of roaster is invariably used in the United States; while both the cylinder and the ball types are popular in England, France, Germany, Holland, and other foreign countries.
An English Four-Machine Gas Coffee-Roasting Plant
The equipment includes three Morewood indirect-flame, and one quick direct-flame machines
Each roasterman has his own opinion about the fuel that gives the best result, and throughout the world the choice lies between anthracite coal, coke, and gas; though hard wood is frequently used in countries where other fuels are not available or not economical. Electric heat has been tried for commercial roasting in Germany (1906), in England (1909), and in the United States (1918); but the experimenters have always found the cost of electric fuel to be prohibitive in competition with coal and gas. An electric roaster was demonstrated at the Food Conservation Show in New York, in 1918, at a time when the federal government was urging the necessity of conserving coal as a war economy measure. The inventor claimed that his machine would reduce roasting cost, improve the flavor and the aroma, and maintain a constant and easily controlled heat. He declared also that when roasted in his devices, less coffee was required for brewing.
An expert coffee-roasting-machinery man who has been working on the development of a practical electric roaster says that if it were possible to bake the coffee in an oven, just as the baker does his bread, the fuel cost would then compare favorably with that of gas or coal. It is because the heat chamber must have an exhaust to release the chaff and smoke that the use of electricity to replace the heat loss proves prohibitive when compared with coal or gas.
In all types of coal and coke burning roasters, the cylinders are heated by a fire underneath; while in gas roasters, the flame may be underneath or within the cylinder itself. Roasters in which the heat is within the cylinder are known as direct-flame or inner-heated machines. All three systems are used in the United States and Europe.
Facts About Coffee Roasting
The modern commercial roasting outfit is as near fool-proof as human genius has been able to devise. The more advanced types are almost automatic in operation, and are designed to insure
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