Coffee roasting workshop for master roasters

With emphasis on roast profiling and consistency of roasting and post-roasting processes

Manuel Diaz
ONA Consulting

Mumbai, India
September 18-21, 2023

Objectives

• To teach advanced sample roasting protocols in quality control laboratories (according

to sample roaster technology and the types of coffee being roasted)
• To develop advanced technical skills to operate industrial roasting systems (control and
monitoring of roasting protocols in production orders).
• To control the roasting processes, identifying critical control points for roasting quality
assurance systems (power, air flow, bean temperature, drum rotation speed).
• To control post-roasting processes (cooling, degassing and stabilization of roasted
coffee)
• To develop the skills needed to design roast profiles according to green bean attributes
(density, moisture content, coffee processing method) and the extraction method to be
applied.
• To control the consistency of roast profiles (scale up roast profiles to an industrial level)
and maintain the consistency of the finished product (color, temperature, weight loss,
roast development, cup profile)

Contents:

1. Advanced physical inspection of the green bean.

a. Physiology of the green coffee bean (cellular structure and chemical composition of the
green bean; network of micropores and layers of cellular tissue; density).
b. Classification of green coffee. Advanced physical standards for the evaluation of green
coffee quality (apparent density, water activity, drying quality, embryo viability, etc.).

2. Control of roasting processes

a. Heat transfer theory and its application to roasting equipment: conduction, convection
and radiation. Evaluation of thermal efficiency and recovery capacity of roasting
equipment.
 b. Roasting machine control systems (gas pressure and power, air pressure and flow rate,
drum rotation speed; actual bean temperature sensor, room temperature sensor, hot air
outlet safety sensor) . Evaluation of the accuracy of thermocouples, rotational speed,
suction pressure and bean mass turbulence.
c. Control of coffee roasting processes (physical and chemical transformations and formation
of compounds in each stage). Main phases of the roasting process; key points to identify
the development of roasting and control parameters (time, temperature, moisture
content, color, weight loss, brittleness, elongation). Critical control points for roasting
processes.

3. Advanced physical and sensory inspection of roasted coffee

a. Roasting process deviations and main roasting defects. Advanced physical inspection of
the final product. Comparative sensory analysis of the same green coffees roasted in
different roasting machines. Identification of roasting defects (uneven, underdeveloped,
baked, snatched and tipping, facing). Advanced standards for high-quality roasted coffees
(physical and sensory inspection).
b. Comparative sensory analysis of finished products. Protocols and formats for roasters.
Benchmarking of finished products.

4. Use of roasting indicators and software

a. Roasting log: from data recording and interpretation to the use of roasting software.
Roasting curves and their impact on the sensory primary attributes of coffee (formation,
peak and degradation of acidity, aromas, sweetness and body in the roasting process).
Exercises to find the optimal point of each sensory attribute.

5. Roasting profiles and blends.

a. Use of roast profiling techniques, according to bean density, flavor profile and blends of
final products. Exercises: roast profiling different beans (processes and origins). Use of
the roasting logs. Interpretation of the curves of environmental temperature (air), real
temperature of the bean and rate of temperature rise (RoR).

b. Modulation of coffee flavor in line with processing methods (i.e. naturals  fruity; wash
 mild). How to adjust roast profiles according to the coffee processing method:
washed, honeys and naturals, dead-embryo long fermentation and new infused coffees,
and special 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.

6. Post-roasting processes and industrial safety

a. Control of post-roasting processes (degassing, stabilization, grinding and packaging)
b. Review of work environments, signs, practices and industrial safety protocols (manuals).
PROGRAM

DAY 1

INTRODUCTION. The coffee value chain and the role of the roasting industry. Importance of the
professionalization of the roasting machinery operator.

1. Classification of green coffee quality (evaluation of physical attributes).

a. Standards and protocols for discriminative evaluation of green coffee samples (odor,
color, shape, size, moisture content and drying quality, density, defects).
b. Green coffee quality classification systems (conventional and special)
I. Bean size distribution and density
II. Relative Density (table)
III. Table of primary and secondary defects
IV. Drying quality
V. Green coffee quality classification system

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. Environmental variables (Relative humidity, temperature)
II. Charging indicators (environmental temperature, air flow, batch size, power)

b. Output indicators
I. Output indicators: final temperature, time, color, weight loss, RDT, power,
airflow
II. Roast quality indicators: Homogeneity, bean elongation and rigidity, flavor
profile

c. Advanced protocols for sample roasting

I. Adjustments according to the sample roasting system
II. Green Bean Density Adjustments
III. Adjustments according to the green coffee processing method (washed and
unwashed coffees)

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

1. Heat transfer theory and its application to coffee roasting equipment:

a. Heat transfer
I. Conduction
II. Convection
III. Radiation

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

c. Role of turbulence and drum rotation speed

d. Role of hot air flow, and positive and negative pressures during the roasting process
e. Key components of a roasting system. Control devices and security measures.

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

b. Key points of roasting development and indicators to identify them (physical

appearance, color, aromas, temperature, time, development)
c. Control parameters of the roasting process (time, temperature, color, weight loss,
brittleness, elongation, development, flavor profile).

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.

Exercise 5: cupping roast defects for sensory evaluation:

• Very fast or flash roast (unevenly roasted, internally underdeveloped and externally
pyrolyzed);
• Underdeveloped roast (raw or weak cup, high acidity but unbalanced, woody and/or
herbal notes);
• Baked roast (long roasting time with insufficient energy, excessive dehydration,
underdeveloped, notes of wood, malt, cooked vegetables, astringent, low acidity and
aromas);
• Overroasted (tipping, facing, charred; smoked and astringent roasts).

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.

Exercise 6: Roasting practice to optimize aroma, acidity, sweetness and body.

Light (and fast) roasts with high power

• 50% development of the first crack
• 75% development of the first crack
• 100% development of the first crack
• 25% development between the end of the first and the beginning of the second crackle

Darker (and slower) roasts at medium power

• 50% development between the end of the first and the beginning of the second crackle
• 90% development between the end of the first and the beginning of the second crackle
• 5 seconds within the second crackle

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

1. Theory of roasting profiles.

 Heat transfer patterns, chemical reaction pathways, sensory curves and flavor
modulation

2. Fast roasting and the Nordic specialty light roasting style

 Fast roasting for very light Scandinavian roasts
 Moderate fast roasting for light specialty roasts

3. Slow roasting for medium to dark roasts

 Slow roasts for medium to medium-dark roasts
 Very slow Italian style roasts for medium dark espresso roasts

4. Hybrid roasting styles

 Roast to perfection

5. Remedial roast profiles

• Exercise 8: Scaling 3 optimal roast profiles (from sample roaster to industrial roaster):

a. fast/light roast for mild coffees;

b. medium to medium dark slow roast for fruity coffees;
c. Complex light and medium light roasts for spicy and complex coffees.

Exercise 9: Conformity evaluation of the finished product according to physical and sensory
standards. Evaluation of consistency and precision in roasting processes.
Day 4

1. Traditions and theories of blending

a. Italian tradition (more than 10 components),
b. European Nordic Tradition (3 components)
c. American specialty tradition (several roasts of the same bean).

2. Sensory analysis and blending

a. Sensory analysis and modulation of coffee flavor
b. Taste dynamics in a blend
i. Bitterness
ii. Acidity
iii. Sweetness (aroma, salts, TDS)
c. Trigeminal sensations
i. Body and texture
ii. Spiciness
d. Character of a blend
e. Aromatic complexity

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.

3. 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.

Exercise 13. Cupping coffees with

• 3 different valves degassing for 3 days whole bean
• 3 different valves degassing for 1 day in ground

Exercise 14. Cupping stabilized coffees for 2 week

• Standard bag with 1 way valve only
• High positive pressure valve
• Double barrier (bag with valve and additional packaging)

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).

Course cost
USD 5,000 plus expenses.

Course schedule and location:

Mumbai, India, September 18-21, 2023.

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.