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Journal of Food Engineering 78 (2007) 1141–1148

www.elsevier.com/locate/jfoodeng

Analysis of the heat and mass transfer during coffee batch roasting
a,*
J.A. Hernández , B. Heyd b, C. Irles c, B. Valdovinos b, G. Trystram b

a
Research Center of Engineering and Applied Sciences (CIICAp), Autonomous University of Morelos State (UAEM),
Av. Universidad No. 1001 Col. Chamilpa, CP 62210, Cuernavaca, Mor., Mexico
b
Joint Research Unit Food Process Engineering (Cemagref, ENSIA, INAPG, INRA) ENSIA, 1 Avenue des Olympiades, 91744 Massy Cedex, France
c
National Institute of Perinatology, Montes Urales 800, Lomas, de Virreyes, CP 11000, Mexico DF

Received 21 May 2005; accepted 19 December 2005


Available online 17 February 2006

Abstract

In this paper, an experimental and theoretical analysis of the heat and mass transfer was carried out to evaluate the coffee bean’s
temperature and moisture content during the roasting in batch system. Arabica coffee from Colombian origin was roasted using different
air temperatures between 190 and 300 C, during 10 min. Bean’s temperature and weight loss have been measured on-line by robust sen-
sors. The experimental results allowed better understanding of the phenomena that appears during roasting. For example, an evident
increase of the bean’s temperature curve tendency is observed when this one exceeds the 250 C, it is probably due to the end of exother-
mic reactions and to the beginning of the bean burn. The experimental data of moisture shown a decrease of 10.5% d.b. to 0–7% d.b. A
dynamic model is evaluated and analyzed to predict bean’s temperature and moisture content during roasting. The results (simulations
and experimental kinetics) were in good agreement. This model can be used for on-line estimation and control of coffee roasting.
 2006 Elsevier Ltd. All rights reserved.

Keywords: Heat and mass transfer; Coffee roasting; On-line measures

1. Introduction (color, volume, mass, form, bean pop, pH, density, volatile
components) and generate CO2, of which a part escapes and
In order to obtain a good cup of coffee, the step of roast- other part is retained in the cells of the beans. After this sec-
ing is very important to develop specific organoleptic prop- ond phase, the beans must be rapidly cooled to stop the
erties (flavors, aromas and color), underlying the quality of reactions (using water or air as cooling agent) and to pre-
the coffee. The amount of heat transferred to the bean is vent an excessive roast which alter the quality of the prod-
essential in the roasting process. The process can be divided uct (Illy & Viani, 1998; Nagaraju, Murthy, Ramalakshmi,
into two phases. The first phase corresponds to the drying & Srinivasa, 1997; Raemy, 1981; Raemy & Lambelet,
(bean’s temperature below 160 C) and the second phase is 1982; Schwartzberg, 2002; Singh, Singh, Bhamidipati,
the roasting (bean’s temperature between 160 and 260 C). Singh, & Barone, 1997; Sivetz & Desrosier, 1979).
In this last phase, pyrolytic reactions start at 190 C caus- During the process, several parameters can be used as
ing oxidation, reduction, hydrolysis, polymerisation, decar- indicators to determine the degree of roasting (aroma, fla-
boxilation and many other chemical changes, leading to the vor, color, bean’s temperature, pH, chemical composition,
formation of substances essential to give among other, the bean pop, mass loss, gas composition and volume) (Dutra,
sensory qualities of the coffee. These moisture loss and Oliveira, Franca, Ferrez, & Afonso, 2001; Hernández,
chemical reactions are accompanied by important changes 2002; Illy & Viani, 1998; Mendes, De Mendes, Aparecida,
& da Silva, 2001; Schwartzberg, 2002). Nevertheless, in the
*
Corresponding author. Tel.: +52 777 3 29 70 84; fax: +52 777 3 29 79
industry, in order to obtain the optimal degree of roasting
84. and to control the quality of the product, the roast master
E-mail address: alfredo@uaem.mx (J.A. Hernández). take up an essential position. In one hand, he interprets the

0260-8774/$ - see front matter  2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.jfoodeng.2005.12.041
1142 J.A. Hernández et al. / Journal of Food Engineering 78 (2007) 1141–1148

physic measure (temperature and time of stay), and in the algorithm is managed in bash (Bourne, 2002); Type K Ther-
other hand, the organoleptic properties of the coffee bever- mocouples allowed to measure internal and external tem-
age (color, aroma and flavor). However, these measures are peratures of the beans and to control the air temperature
obtained out-line. Automation is limited by the lack of cap- with a precision of ±0.5 C. One bean is drilled in order
tors allowing to follow the quality in real time, and by the to insert a thermocouple 4 mm below the surface (internal
process conditions (the mass of beans is always in agita- temperature), and another thermocouple about 0.2 mm
tion) which make instrumentation difficult (Hernández, below the surface in order to measure the near surface tem-
2002; Schwartzberg, 2002). It is important to mention that perature (see Fig. 1B). The beans are placed on a mesh to
the control of temperatures and duration, in industry, are keep them on static suspension, where convection is the
only effective, if the quality of the raw material does not predominant mode of heat transfer. Beans weight is auto-
vary. Today, the chemical reactions are extensively studied matically measured using an electronic scale METTLER
by Illy and Viani (1998), nevertheless, coffee roasting is (SB16001) and controlled by the computer (see Fig. 1A).
slightly studied as an unit operation. Indeed, in this opera- A program written in bash makes the weight acquisition
tion, a specific instrumentation, working in real time and each minute. Before each weight acquisition, the fan of
taking into account the variables of the product does not the roaster is automatically stopped for 8 s to stabilize
exist. Several variations are presented as a function of the the measure.
raw material and of the process conditions. The aim of this
work is to measure and analyze the bean temperature and 3. Results
moisture content during coffee roasting and to evaluate the
model in the purpose of process control. During coffee roasting, mass and temperature are mea-
sured on-line. The results will allow a better understanding
2. Material and methods of the process, and a validation of the mathematical model.
Fig. 2 shows the evolution of the internal and external
Colombia green coffee beans (Arabica) are roasted using bean’s temperature and of the air temperature (C) during
hot air flow as heating medium. The experiments are car- the roasting. These curves (Fig. 2) put in evidence the effect
ried out at constant air velocity of 4 m/s for constant air of the air temperature on the evolution of the bean’s tem-
temperatures (190, 200, 210, 220, 230, 240, 250, 260, 270, perature. The internal bean’s temperature has an exponen-
280, 290 and 300 C) during 10 min. The experiments are tial behavior described by Schwartzberg (2002) if bean’s
done with three replicates. temperature is below 250 C.
Fig. 1 depicts the data acquisition and processing using An evident deviation with exponential kinetic is
a computer equipped with a temperature acquisition sys- observed between 80 and 100 s of roasting (Fig. 2B) for
tem (SCB7 thermocouple conditioner and Arcom experiments where the bean’s temperature become higher
PCAD12/16H A/D converter) and several software. The than 260 C. When the optimal bean’s temperature is sur-
low level task (data acquisition and I/O port programming) passed, the exothermic reactions responsible of the aroma
are written in C (Lawyer, 2000; Photis, 1999), real time and flavor are reduced and the beans begin to be burn. This
data processing are done with Octave (Eaton, 2001) and phenomenon is called over-roasting by Coste (1968), it can

Thermocouples
carte ADC carte Bean Coffee
SCB7
C

captemp
(write in
bash)

fichie R
(data)
R
octave R
relais balance
fichie
Tempe- balance (data)
ratures capmas
(in bash)
octave
cafe.ensia.inra.fr relais C
Mass
A B

Fig. 1. Scheme of experimental data used (temperatures and mass).


J.A. Hernández et al. / Journal of Food Engineering 78 (2007) 1141–1148 1143

200 350

180
300
160 Air Temperature
Temperature (°C) 250 Air Temperature

Temperature (°C)
140
Surface Bean Temperature
120 200 Surface Bean Temperature

100 150
Bean Temperature
80
100
Bean Temperature
60

40 Air Temperature 190 °C 50


Air Temperature 300 °C
20 0
0 50 100 150 200 250 300 350 400 0 50 100 150 200 250
A Time (s) B Time (s)

Fig. 2. Evolution of bean’s temperatures for roasting at 190 and 300 C.

be responsible of the observed deviation. Consequently, and below 5% d.b. in roasted coffee. Furthermore, volatile
this confirm that the bean’s temperature versus the time components are formed during roasting, inducing also
can be an indicator of the roast-degree during coffee roast- noticeable mass loss. Dutra et al. (2001) determined weight
ing. It is important to mention that Schwartzberg (2002) loss during the process for 300 g of green coffee using a
stopped the process when the bean temperature reach direct heating. They found two different speeds for mass
238 C, so he never observed this phenomenon. loss: the first period, between 0 and 7 min, shows a linear
During roasting, weight loss is measured each minute. kinetic with a weak slope, this period corresponds to a
The results in Fig. 3, show that we obtained a good repeat- moisture and volatiles losses, the second period from 7 to
ability of the measures (two repetition at 300 and 190 C, 12 min the weight loss follows a right line with a strong
and three at 250 C). After a short stage of latency, we slope, and this corresponds to a loss of CO2 and organic
observe a quasi linear behavior followed by a marked components of the bean. Besides, they showed that loss
deceleration. Weight loss clearly depend on the air temper- of CO2 increases when the moisture content diminishes sig-
ature of the roasting time. After 10 min of process the per- nificantly. The evolution of the mass loss can therefore be a
centage of mass loss ranged from 3% to 12% depending on criterion of the roasting degree, but it is not a key criterion
roasting temperature. Similar results are reported by sever- for us because weight is difficult to measure on-line in the
als authors (Da Porto, Nicoli, Severini, Sensidoni, & Lerici, industry.
1991; Dutra et al., 2001; Pittia, Dalla, Pinnavaia, &
Massini, 1996; Schwartzberg, 2002). This authors also 4. Heat and mass transfer modelling
reported weight loss differences due to types of roasting
machines, duration, type of bean and air temperature. The heat and mass transport mechanisms during batch
According to Guyot (1993) and Illy and Viani (1998), roasting (roaster using hot air flow) are given by the equa-
the moisture content is about 8–12% d.b. in green coffee tions proposed by Schwartzberg (2002):

• Moisture loss, the diffusive water transport in the bean is


14
given by
 
12 T’air 300 °C dX 4:32  109  X 2 9889
 ¼ exp  ð1Þ
10 dt d 2p T b þ 273:15
Weight Loss (%)

8 X: moisture content (kgwater/kgdry matter); Tb: internal


T’air 250 °C
temperature of the bean (C). The water loss is governed
6 by an Arrhenius type equation, proportional to X2; and
4 dp: effective bean diameter.
• Heat transfer, the rate of temperature rise of the beans is
2 given by
T’air 190 °C  
0 dT b GC pa ½T ae  T as   Qa!m þ Qm!b þ mbs Qr þ Lv dXdt
0 100 200 300 400 500 600 ¼
Time (s) dt mbs ð1 þ X ÞC pb
Fig. 3. Experimentals kinetics of weight loss. ð2Þ
1144 J.A. Hernández et al. / Journal of Food Engineering 78 (2007) 1141–1148

where Tae and Tas are respectively the in-air and out-air where, Ha is the energy of activation, Rg is the perfect-
temperature (C). G is the air mass-flow rate (kg/s). Cpa gas-law constant, A, in kJ/(kg dry coffee) s, is the
and Cpb are respectively the air and bean heat capacity Arrhenius equation prefactor times the amount of heat
(kJ/kg C). mbs is the dry weight of the bean kg dry generated per unit amount of reaction.
coffee and Lv is the latent heat of vaporization of the Schwartzberg (2002) obtained HRga ¼ 5500 K, A = 116,200
bean moisture, Schwartzberg (2002) gives 2790 kJ/kg. kJ/(kg dry coffee) s and Het = 232 kJ/kg.
Measured bean properties:
In this balance Eq. (2), the heat transfer from hot air to
bean GCpa[Tae  Tas], the heat transfer from air to metal • Aab = 1.4 · 104 m2 equivalent sphere area.
parts Qa!m, the heat transfer from metal parts to beans • mbs = 1.75 · 104 kg dry matter.
Qm!b, the heat production by roasting reactions Qrmbs • db = 6.6 mm equivalent sphere diameter.
and the heat necessary to moisture evaporation at the bean
surface during the roasting Lv ðdXdt
Þmbs are considered. How- 4.2. Model solution
ever, in this work, the contact area between coffee beans
and metal part is negligible. It is also possible to assume To solve the system of Eqs. (1)–(7), we wrote a computer
that the heat transfer from hot air to metal is negligible program in Octave (Eaton, 2001). This program works in
because the temperature of the metal is equal to the air the following way: at instant t = 0, we know:
temperature. Under this two hypothesis, the model is sim-
plified as follows: • the initial bean temperature Tb initial = 29 C,
 
dT b GC pa ½T ae  T as  þ mbs Qr þ Lv dX • the initial bean moisture X initial = 0.105 kg water/kg
dt
¼ ð3Þ dry matter,
dt mbs ð1 þ X ÞC pb
• the in-air temperature Tae, measured on-line.
To determine [Tae  Tas] in Eq. (3), a balance of air temper-
ature is considered by Schwartzberg (2002). Under the pre- These data allow to calculate in time t = 0:
vious hypothesis, it is possible to write:
   • the effective air-to-bean heat transfer coefficient a (Eq.
aAab
½T ae  T as  ¼ ðT ae  T b Þ 1  exp  ð4Þ (5)),
GC pa
• the out-air temperature Tas (Eq. (4)),
where a is the effective air-to-bean heat transfer coefficient • the rate of moisture loss dX
dt
(Eq. (1)),
(W/m2 C), Aab is the area (m2) across which air-to-bean • the specific heat of the coffee bean Cpb(1 + X) (Eq. (6)),
heat transfer occurs. • the rate of exothermic heat production Qr (Eq. (7)).

4.1. Properties estimation The set of differential equations was numerically inte-
grated using fourth-order Runge–Kutta method written
To solve Eq. (2) by considering Eq. (4), it is necessary to in Octave (Eaton, 2001).
know a, Cpb and Qr:

• Effective air-to-bean heat transfer coefficient, a, was esti- 4.3. Simulation of the heat and mass transfer
mated by Eq. (5) reported by Schwartzberg (2002):
An important characteristic of the model is that no param-
he
a¼ ð5Þ eter was adjusted to describe the bean’s temperature and
1 þ 0:3  Bi moisture content. The program was written in order to esti-
where, he is the heat transfer coefficient at the air–bean mate the bean’s temperature and moisture content versus
surface calculated by the Ranz–Marshall correlation time, for a hot air roaster with 25 g of green coffee in different
(Perry & Green, 1998) and Bi (Biot number) is used to constant air temperatures (Tae from 190 to 300 C).
correct the overall air–bean heat transfer coefficient for Fig. 4 shows agreement between experimental and sim-
heat transfer resistance in the bean (Kreith, 1967). ulated bean’s temperature for three roasting temperatures.
• Specific heat of the coffee bean, Cpb, the values used are This three kinetics are representatives for all the experi-
obtained by Eq. (6) reported by Schwartzberg (2002): ments. Below 250 C, the model fits very well the data.
C pb ð1 þ X Þ ¼ 1:099 þ 0:0070T b þ 5:0X ð6Þ For hight bean’s temperature, the model do not predict
the small deviation which we had already observed in the
• Exothermic roasting reaction, Qr (rate of exothermic experimental part (Fig. 2B). The deviation can be explained
heat production), in kJ/(kg dry coffee) s, was calculated by a beginning of an over-roasting, the exothermic reaction
using Eq. (7) reported by Schwartzberg (2002) parameters (Eq. (7)) given by literature are not valid for
   this experimental domain. Consequently, the model cannot
Ha H et  H e
Qr ¼ A  exp  ð7Þ consider this perturbation. It could be possible to add an
Rg ðT b ðKÞÞ H et other factor to take this phenomena into account, but we
J.A. Hernández et al. / Journal of Food Engineering 78 (2007) 1141–1148 1145

350 and CO2; the model, which only considers water loss,
T’air 300 °C should give higher results. It would be interesting to mea-
300
sure the water content of the beans during roasting, and
Bean Temperature (°C)

250 T’air 240 °C to develop a more physical model considering water diffu-
sivity in the bean and mass transfer coefficient between
200 T’air 190 °C bean and air. But the perturbation of bean’s temperature
model induced by the bad estimated water loss is negligible.
150
Bean reach the roasting air temperature in less than 180 s,
100 and the moisture content simulation become bad after
300 s of roasting, when the heat transfer is very low.
50

0 4.4. Sensitivity analysis


0 50 100 150 200 250
Time (s) As shown in the previous section, the model reproduced
Fig. 4. Evolution of the bean’s temperature versus time for different air with good accuracy the experimental data (Tb and X).
temperatures (*: experimental, -: simulated). However, this model is developed for process control pur-
pose, as a consequence it is important to test the robustness
of the model for small perturbations of the process vari-
preferred to keep a robust model with no adjusted ables (Va, HR) or of the product characteristics (a, Aab, db,
parameter. X, Cpb, Qr, mbs).
The moisture content simulation using Eq. (1) leads to A variation of air velocity, Va, from 2 to 6 m/s induces
acceptable results (Fig. 5) for the beginning of the kinetic. important changes on the Tb (see Fig. 6). This change
After 300 s the model significantly underestimates the can be explained, since the air velocity have an effect on
water content. The weight loss include water, volatiles the heat transfer coefficient calculated by Ranz–Marshall
correlation (Perry & Green, 1998) he and the air mass-flow
rate G. These two parameters are very important to predict
0.105
the bean’s temperature and out-air temperature (see Eqs.
0.1 (2) and (3)). Therefore, it is necessary to know the air veloc-
ity in an exact way.
X (g H2O/g Dry matter)

0.095
A variation of relative humidity, HR, from 20% to 80%
0.09 (at ambient temperature) did not show an effect on the sim-
ulated bean’s temperature (data not shown), since when air
0.085 T’air 220 °C is heated at 200 C, it become very dry (HR < 0.1%).
0.08 Fig. 7 shows the effect of the bean’s size (db) on the
bean’s temperature versus time. One can observe that the
0.075 variations of db have a very important effect on the bean’s
temperature Tb as mentioned by Schwartzberg (2002).
0 100 200 300 400 500 When we consider a relatively small variation of bean’s
Time (s) dimensions (Aab), the prediction of the bean’s temperature
Fig. 5. Evolution of the bean’s moisture content (*, +: experimental, -: vary appreciably (Fig. 8), thus this parameter Aab must be
simulated). known with precision, because this value will reflect itself

0 20 40 60 80 100 120 0 20 40 60 80 100 120 140


300 300
Bean Temperature (°C)

Bean Temperature (°C)

200 200 250 250

200 200
150 150
150 150
100 100
100 100
T’air=240 °C T’air=300 °C
50 Va = 2, 4, 6 m/s 50 Va = 2, 4, 6 m/s
50 50

0 20 40 60 80 100 120 0 20 40 60 80 100 120 140


Time (s) Time (s)

Fig. 6. Bean’s temperature versus time, (-): Va = 2, (): Va = 4 and (+): Va = 6 m/s.
1146 J.A. Hernández et al. / Journal of Food Engineering 78 (2007) 1141–1148

0 20 40 60 80 100 0 20 40 60 80 100
250 250
300 300

Bean Temperature (°C)


Bean Temparature (°C)
200 200 250 250

200 200
150 150
150 150
100 100
100 100
T’air=240 °C T’air=300 °C
50 db = 4, 5, 6, 7 mm 50 50 db = 4, 5, 6, 7 mm 50

0 20 40 60 80 100 0 20 40 60 80 100
Time (s) Time (s)

Fig. 7. Evolution of bean’s temperature versus time (line continuous) represents d = 4, (line discontinuous) is d = 5, (+) is d = 6 and (*) is d = 7 mm.

0 50 100 150 200 250 300 350 Fig. 9 presents the results of bean’s temperature versus
250 250 time for different initial moisture contents X0. These curves
show well that it exists a minor effect on the values of
Bean Temperature (°C)

200 200 Tb. However, if initial moisture content is considered as null


(X0 = 0), the simulated beans temperature increased
150 150
quickly, it is normal, because the phase of drying does
not take place. Therefore, the initial moisture is a very
100 100
important factor that must be considered in the model
-- Aab 0.03 m 2
50 - Aab 0.02 m2 50 bean’s temperature prediction, but the analysis of the ini-
tial moisture value X0, of 9%, 11% and 13% in d.b., have
0 50 100 150 200 250 300 350
shown that the effect of this parameter on the kinetics of
Time (s)
bean’s temperature is rather weak (see Fig. 9).
Fig. 10 compares the two bean’s temperature kinetics,
Fig. 8. Variations of Aab in Eq. (2). first using a constant Cpb (2.41 kJ/kg C) and the other a
variable Cpb f(X, Tb) (Eq. (6)). Also, this figure shows the
on the results of Tb. Besides, according to Eq. (4), the experimental data (indicated by *) of the bean’s tempera-
dimensions of the bean tends to be a very influential ture. It can be observed that the constant specific heat of
parameter on Tb, Tae and Tas. These dimensions can vary the bean can also simulate the bean’s temperature but in
according to the batch of coffee to be roasted and during a way less satisfactory than if one uses a variable Cpb for
the course of the process Hernández (2002). When a mix- the bean’s temperature of roasting. Nevertheless to predict
ture of varieties (i.e. Arabica and Robusta) is roasted, these bean’s temperature over 260 C is better to use the constant
dimensions are delicate to determine in the batch and dur- Cpb but this it is not the case because carbonization begins.
ing the process, and by consequence a model to predict Aab In addition, the dry weight of the beans mbs has also
is necessary inside the system of proposed equations. shown a change in the behavior of Tb versus t. To recapit-

0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80

250 250
200 200
Bean Temperature (°C)

Bean Temperature (°C)

200 200
150 150
150 150
100 100
100 100
T’air=240 °C T’air=300 °C
50 X0=9, 11, 13 % d.b. 50 X0=9, 11, 13 % d.b.
50 50

0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80
Time (s) Time (s)

Fig. 9. Bean’s temperature versus time, line continuous is X0 = 9%, line discontinuous is X0 = 11%, + is X0 = 13% d.b.
J.A. Hernández et al. / Journal of Food Engineering 78 (2007) 1141–1148 1147

0 50 100 150 200 250 300 350 0 20 40 60 80 100 120 140 160
250 250 300 300

Bean Temperature (°C)

Bean Temperature (°C)


200 200 250 250

200 200
150 150
150 150
100 T’air=240 °C 100 T’air=300 °C
100 100
-- Cpb= constant (2.41), -- Cpb= constant (2.41),
50 - Cpb= variable f(X,Tb) 50 - Cpb= variable f(X,Tb)
50 50

0 50 100 150 200 250 300 350 0 20 40 60 80 100 120 140 160
Time (s) Time (s)

Fig. 10. Bean’s temperature versus time, (line continuous) represent the variable specific heat of the bean (Eq. (6)) and (line discontinuous) is a constant
Cpb = 2.41.

ulate this analysis of succinct sensitivity of the dynamic cult to measure on industrial roaster, but we showed that
model, we showed that if the changes of operation vari- it is possible to calculate this temperature as a function
ables and parameters linked with the product like: of input temperature Tae. The model calculates the output
air temperature Tcas at the same time, which is easy to mea-
• the specific heat Cpb, sure on-line. If some perturbation appears, that it is not
• the mass of product m, take into account by the model, the simulated bean’s tem-
• the air velocity Va. perature Tcb , will be wrong, this will appear on the differ-
ence between simulated and experimental temperature
The model takes into account these parameters in order ð Tcae  T ae Þ, allowing to adjust the model parameters on-
to predict the bean’s temperature in a satisfactory manner. line. Further studies will try to adapt this strategy to indus-
For variables not controlled by the model as: trial roaster.

• dimensions of the bean db (diameter) and Aab (surface of Acknowledgment


the bean),
• initial moisture X0. We thank to Prof. Henry G. Schwartzberg for his per-
sonal communication to this work.
It is necessary to measure the correct values in order to
have a reliable model. Some variables, like relative humid- References
ity HR, does not influence the output of the model, under
the studied conditions. Bourne, S. (2002). Bash (free software). In Bourne Again SHell. Available
from http://www.gnu.org/software/bash/bash.html, consulted April
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197–207.
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