At the same time, however, it’s also important for roasters to offer products which suit a range of customers’ needs, including pre-ground coffee. These products are ground and packaged at the roastery, before roasters sell them to consumers.

Given that ground coffee is highly sensitive to a number of environmental conditions, it’s absolutely imperative that roasters seal and package pre-ground coffee as safely and effectively as possible.

To learn more, we spoke with Gian Pietro Balboni, Process Engineer at IMF Roasters. Read on to find out more about packaging and selling ground coffee.

You may also like our article on how roasters can store and transport roasted coffee safely & effectively.

Why should roasters sell pre-ground coffee?

For near enough any specialty coffee roaster, whole bean coffee serves an important purpose. By grinding coffee just before brewing, wholesale customers and consumers alike can guarantee their coffee tastes fresher and better.

However, not all coffee consumers will have access to a grinder – or may not want to invest in one altogether. 

Moreover, a US survey from 2020 found that 76% of people purchased their coffee pre-ground. While this percentage certainly varies from country to country, it’s clear that there is demand for pre-ground coffee.

It’s important to remember that convenience is a major purchasing factor for many consumers. And while price and quality are also key points to consider, some studies have found that nearly half of consumers believe convenience is more important than price when deciding where to shop.

Ultimately, for many consumers, pre-ground coffee is highly convenient. On top of that, there has also been a massive increase in the popularity of pods and capsules, as well as single-serve bags.

At the same time, however, pre-ground coffee products still need to be high-quality to make sure that consumers experience the full range of a coffee’s sensory profile.

Why do roasters need to package ground coffee safely and effectively?

Roasted coffee – whether ground or whole bean – is an unstable product. This is because many chemical reactions take place when roasters apply high temperatures to green coffee. These reactions then create irreversible changes within the cell structure of the coffee beans – and thereby help to develop its flavours and aromas.

During the roasting process, a number of gases – including carbon dioxide (CO2) – form inside coffee beans. Although the roasting process causes some CO2 and water vapour to release, the majority of it remains trapped inside the beans.

Pre-ground coffee, however, is even more unstable than whole bean. This is because when you grind coffee, it releases around 60% to 70% of its CO2 content. This is an indicator of an immediate loss of freshness.

Research has found that the amount of CO2 contained in coffee is a “physical” marker of freshness. Essentially, the more CO2 there is in coffee, the more “fresh” it is.

“Ground coffee also degrades easily when in contact with oxygen because of the oxidation process, which is the main reason for loss of freshness and aroma,” Gian says.

Considering this, it’s important that roasters implement strict protocols and procedures to protect the integrity of ground coffee. If the appropriate controls aren’t put in place, the risk of contamination, as well as the loss of quality and freshness, becomes all too prevalent.

This is mainly because when coffee is ground, the surface area of the coffee beans increases significantly. Essentially, this increases the coffee’s exposure to a number of different variables, including:

• Oxygen
• Heat
• Sunlight

Over a long enough period of time, prolonged exposure to these factors will inevitably lead to a loss of flavour, aroma, and freshness.

Concerns about selling pre-ground coffee

Some specialty coffee roasters may be hesitant about selling pre-ground coffee at all – mainly because the challenges with freshness can be associated with a loss of quality. However, contamination is another challenge to keep in mind.

As ground coffee has a larger surface area – and therefore more exposure to elements and variables – than whole bean coffee, there are more opportunities for contamination. For instance, ground coffee will naturally absorb more moisture, odours, and flavours from its surrounding environment.

Although the roasting process is typically considered a “kill step” (the point where any potentially dangerous pathogens and microorganisms are removed from the product), ground coffee is still susceptible to contamination. This is especially true when it is stored, transported, or packaged improperly.

In light of this, roasters need to ensure that their pre-ground coffee products are stored, transported, and packaged in a way that mitigates exposure to any potential hazards.

What equipment do roasters need?

To sell high-quality pre-ground coffee products, roasters need to ensure they have the right equipment for storage, transportation, and packaging.

“Ground coffee is very sensitive to certain variables, and has a shorter shelf life,” Gian says, therefore packaging needs to elongate shelf life as much as possible. 

Pre-ground coffee products are moved around a lot, ranging from handling by roasters, to transportation, to the consumers themselves.

By the time roasted coffee is ground, packaged, and then sent to the consumer, there is significant potential to lose quality.

To address these issues, roasters need to consider storage systems first.

“IMF’s ground coffee storage systems are designed to preserve freshness and quality,” Gian tells me. “We design specific storage silos which reduce any contact between ground coffee and oxygen in the surrounding environment.”

Nitrogen flushing

As exposure to oxygen is one of the primary factors which reduces the shelf life of ground coffee, some roasters flush the oxygen out of their packaging, replacing it with nitrogen.

“IMF also provides storage systems which allow nitrogen to enter the silo,” Gian explains. “This preserves more aromatic compounds during the degassing phase. 

“The nitrogen-flushing system expels oxygen from the silos,” he adds. “The silos are then under controlled conditions so that there is no contact between ground coffee and oxygen for better aroma preservation.

“Our silos also have high vacuum cycles which forcibly extract CO2 from ground coffee in less time than the typical degassing phase,” he continues.

Roasteries of any size can implement systems like these, but it largely depends on their budgets.

Degassing

“Product freshness and preservation of quality are necessary to assure that residual CO2 in ground coffee is suitable for packaging,” Gian says. This is particularly important, otherwise bags can expand and rupture if the coffee hasn’t been left to degas for a sufficient amount of time.

Considering this, degassing valves can be particularly useful. These are usually contain a cap, an elastic disc, a viscous layer, a polyethylene plate, and a paper filter. As pressure builds up when CO2 gradually releases from coffee, it will eventually pass the surface tension. Following this, the viscous layer will displace the diaphragm, allowing the excess CO2 to escape.

Selling ground coffee is a successful income stream for many roasters, but it’s essential that they know how to store, transport, and package these products as effectively as possible.

Throughout this process, roasters also need a comprehensive plan for preserving freshness (and therefore quality) every step of the way – both before the coffee is roasted and ground, and afterwards.

Enjoyed this? Then read our article on how specialty roasters manage their green coffee supplies.

Photo credits: IMF Roasters

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On top of this, shipping costs for roasters have also increased – squeezing already-slim profit margins more than ever.

Ultimately, it’s important that roasters are able to keep their business costs down to remain profitable. So what are some of the ways they can do this?

To find out, I spoke to three roasting professionals. Read on for more of their insight.

You may also like our article on whether coffee roasters should add robusta to blends if arabica prices increase again.

Why are costs rising?

Over the past two years, hospitality businesses have been facing a number of significant challenges. As a result of Covid-19 lockdown measures in early 2020, many coffee shops and roasters were forced to temporarily close. 

At the time, many business owners were concerned about remaining profitable. According to a UK survey conducted in 2020, nearly 50% of coffee shop owners in the country believed that Covid-19 would significantly affect their revenue until the end of that year.

While there has been some financial recovery following the pandemic, we have seen costs (particularly for food and energy) continue to increase for coffee businesses for several reasons. 

The pandemic has undoubtedly contributed to the ongoing energy crisis as more people than ever before worked and remained at home, meaning demand for energy skyrocketed. 

On top of this, the Russian government’s invasion of Ukraine has worsened the situation – leading to record gas prices and potentially resulting in high energy and food prices for the next three years.

Perpinias Kostas is the owner of Mr. Bean Coffee Company, a roastery in Athens, Greece. 

“In the last few months, roastery operation costs have increased significantly,” he says. “Following the pandemic, the price of shipping containers increased drastically, the price of coffee increased, and the US dollar strengthened against the euro. 

“The energy crisis also increased the cost of packaging materials and fuel for transportation and shipping,” he adds. “This means costs for roasters have skyrocketed, and it’s difficult to not pass these costs onto the consumer, so profits have also been decreasing.”

Furthermore, rising energy and food costs are also impacting consumers. According to research from Deloitte published in October, some 30% of UK consumers are spending less money – up from 21% at the start of 2022. 

Ultimately, this challenging economic climate makes it more important than ever for roasters to keep their costs down.

Breaking down the costs of roasting

Before we can discuss how roasters are able to minimise their costs, we first need to break them down. There are many business costs which roasters need to consider – including equipment, rent, energy bills, shipping and transportation, and more.

Ioannis Papadopoulos is the owner and 3D Mechanical Designer at IP-CC, a roaster manufacturer in Thessaloniki, Greece.

“Purchasing equipment and machinery is often the first – and biggest – upfront cost,” he says. “Roasters, afterburners, and storage silos for both green and roasted beans are essential pieces of equipment in any roastery.”

In order to keep green coffee fresh and free from contamination, it must be stored in cool and dry conditions with as little exposure to oxygen and light as possible. Storage silos help to maintain these conditions, making them essential pieces of equipment for any roaster.

“Moreover, the majority of roasters also need to buy equipment which best suits their needs, so purchasing customised or specialist equipment can significantly increase these costs,” he adds.

Specialist equipment can include custom-branded roasters, machines which have integrated software or smart technology, or more energy-efficient roasters.

Ioannis explains other major business costs which roasters need to account for.

“There are staff wages and the costs of packaging roasted coffee, too,” he says. “You also need to factor in buying green coffee and having a large enough space for roasting and storing coffee.

“It takes around seven to ten days for freshly roasted coffee to degas, which means adequate storage space for roasted coffee is essential,” he adds.

For smaller roasters looking to expand their operations, there are also other business costs which need to be considered. 

“When a smaller roaster expands to become a medium or large-sized coffee business, the costs of training and paying more experienced and skilled staff will increase,” Ioannis explains. 

As a roaster scales its business, the volumes of roasted coffee it sells will also naturally increase – meaning the costs associated with operating machines will as well.

Cost management tips

Considering the numerous costs which roasters need to pay attention to, it can be a daunting task to know where to start reducing spending. 

One of the most significant ways in which roasters can minimise long-term costs is investing in a more efficient and sustainable roaster. 

While older gas-powered machines can roast coffee to a high standard, they can be much less efficient than modern roasters. And with natural gas prices continuing to increase around the world, making the shift towards machines which are less dependent on gas can help roasters minimise their running costs.

“IP-CC understands that investing in new roasting technology and more efficient machines can help roasters to reduce their costs,” Ioannis tells me. “It’s important for roastery owners to understand that adopting new technologies will help them to upgrade and develop their businesses in the long run.”

Having more control over heat dispersion has been an area of focus for specialty roasters for some time now, as it can help them get the best results from their coffee.

One example of an efficient automated roaster is IP-CC’s iRm series machines, which use hot air technology to roast coffee. 

Ioannis tells me the roasters create up to five times the volume of hot air than other commercial machines – as well as up to five times quicker air speed – which he says can help to cut down on a roastery’s costs by up to 50%.

Michalis Katsiavos is the 2018 Hellenic Barista Champion. He also works at Seven Steps Coffee Roasters in Ilion, Greece, where he uses a 5kg-capacity iRm roaster.

“Investing in a more efficient machine is key to helping roasters manage their costs more effectively,” he says. “Roasters that use hot air technology can save between 30% to 40% propane consumption, [which ultimately reduces your costs, too].”

Furthermore, more efficient roasters also tend to be better insulated, which means energy conservation can improve. For instance, IP-CC’s iRm machines are thermally insulated, and also include a smokeless air supply, which can help to reduce costs further.

“In addition to this, this smokeless roasting style can result in more uniform roast profiles, as well as cleaner-tasting coffee,” Michalis explains.

What are the other areas where roasters can reduce spending?

Alongside investing in a more modern and efficient machine, there are other ways in which roasters can minimise costs – such as staffing.

Traditionally, medium and large-sized roasters require a team of staff, which will include a head roaster. This is because production roasting on a large-capacity gas-powered roaster requires a professional overseeing the entire process to make sure consistency is kept high.

However, with the rise of automation and AI-technology in roasting, roasters’ job roles are changing, and they are now winning back more time to focus on other areas of the business. These can include marketing and branding, product development, and improving sustainability practices.

Many newer machines, such as the iRm series, allow roasters to connect specialist software programmes like Cropster and Artisan. In turn, this grants roasters more control over their roast profiles, helping them improve precision and giving them the ability to experiment with more parameters.

Moreover, this grants roasters more time to experiment with their roast profiles, as opposed to repeating them to get the best results.

“Roasting on an iRm allows me to control the temperature in the drum, so that I can enhance the best qualities of the coffee, such as sweetness and juiciness,” Michalis explains.

It’s more important than ever for roasters to keep a close eye on their costs, and profitability is a key question as we enter an environment of economic uncertainty.

While there are many ways for roasters to cut down on costs, investing in a more energy-efficient machine can be a great place to start. Similarly, automating production roasting can give roasters more time to focus on other aspects of the business – such as sales and marketing.

Enjoyed this? Then read our article on why blends are becoming more popular in specialty coffee.

Photo credits: IP-CC

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However, with demand for sustainable coffee continuing to increase, as well as soaring shipping and energy costs, roasters are looking for new ways to appeal to consumers and reduce their spending. One of these includes investing in electric roasters.

So how do electric machines work, and which factors do roasters need to consider when using one? To find out, I spoke to two coffee professionals who work with coffee roaster manufacturer Stronghold. Read on to find out what they had to say. 

You may also like our article on choosing a roaster for your coffee shop.

Exploring different types of coffee roasters

In previous decades, gas was the most commonly used energy source for roasting coffee – no matter which type of roaster was used. Drum and fluid bed roasters are the most common types of machines, with both capable of roasting coffee to a high standard of quality, whether using gas or electricity.

But in recent years, there has been a greater focus on electric machines, which allow roasters to have much more control over different variables.

Amir Navid is the CEO and founder of Kühne Kaffee in Hamburg, Germany – a regional distributor of Stronghold roasters.

“Comparing an electric roaster to a gas roaster is like comparing a Tesla with an old diesel car,” he says. “When roasting using gas-powered machines, roasters often have to make a lot of adjustments to their variables.

“But nowadays, roasters have to spend a lot more time on marketing their businesses,” he adds.

Traditionally, roasters would have to pay close attention to a number of different roast variables, such as temperature and total roast time. However, with the recent rise of electric machines, which often champion automation, roasters are able to spend more time away from their machines and focus on other areas of their business.

“[In some countries], you may also need to own a special licence and a certain type of insurance because of the carbon emissions produced,” Amir says. “Moreover, you also need to account for the additional costs of installing pipes and an afterburner when using a gas-powered roaster.”

Why are more roasters using electric machines?

There are a number of reasons why electric roasters are becoming more popular. One example is the ever-growing demand for more sustainable coffee.

Now more than ever, consumers expect the coffee they buy to be more sustainable. And while a large part of this is centred around more transparency and traceability in the supply chain, sustainability also extends to coffee roasting, too.

Traditional gas-powered roasters can emit several pollutants, such as nitrogen oxide, carbon monoxide, and carbon dioxide. These gases are not only harmful to the environment, but they can have serious effects on human health if inhaled in significant volumes.

Furthermore, these roasters rely on fossil fuels (mainly natural gas) to operate, which are known to contribute to global warming.

As well as this, in recent months, we have seen the price of natural gas rise sharply as a result of the conflict in Ukraine and economic sanctions placed on Russia.

Naturally, this means that the costs of operating a gas-powered roaster have also spiked – tightening many roasters’ margins and forcing them to look for ways to reduce spending.

“Roasters are looking for opportunities to minimise the uncertainty around fluctuating gas prices, as well as the possibility of supply shortages,” Amir explains.

For roasters who use gas-powered machines, the equipment is typically connected to a shared gas supply, which may also be used to heat the workspace, among other things. 

This can also have an impact on the roaster. During colder months, for example, while the central heating is used more frequently, the pressure could drop in the roaster, potentially leading to less consistent roast profiles. 

However, with electric machines, roasters can largely bypass these issues.

Alex Lee is the North America Regional Representative for Stronghold. He explains how electric roasters, such as the automated S9X smart roaster, can work more efficiently and accurately than gas-powered models.

“Rather than manually controlling gas flow, the roaster can manage all of their variables electronically throughout the entire roast,” he says.

Over the past few years, automation and AI have become more widely used in coffee roasting. In essence, these technologies allow roasters to better replicate roast profiles and to improve data analysis and application, thereby also improving coffee quality.

“In theory, a roaster should be able to perform as well as the manufacturer claims it can,” Alex tells me. “However, other variables like the roasting environment, maintenance issues, and even the coffee itself can affect performance.

“When you use gas, no matter how precise the roaster’s electronic control panels are, the energy generation is still too volatile to [have a higher level of control],” he adds. “By using electric automated roasters, we are able to mitigate potential errors as much as possible.”

Understanding how electric roasters work

For roasters to successfully transition from gas to electric roasters, they first must understand how the machines operate differently.

By far the most important factor to consider is the difference in heat transfer. In general, electric machines have more advanced heat transfer systems, which means roasters are better equipped to control a number of variables.

“Stronghold’s S9X electric roaster, for example, has a triple heat management system,” Alex explains. “This includes heat transfer through convection, radiation, and conduction, and the roaster can control all three methods independently of each other.

“This means you can develop roast profiles more purposefully, as well as having the ability to experiment more,” he adds. 

In theory, having more control over different types of heat transfer allows roasters to more precisely control a roast. This can help them get the best out of a given coffee, and maybe even unlock a new flavour profile entirely.

“However, there are a number of factors which can influence how heat transfers from the machine to the coffee, such as the size and density of the beans, as well as varying levels of sugars contained within the beans,” Alex says.

Ultimately, roasters need to account for these differences when developing their roast profiles in order to get the best results from their coffee.

Temperature stability is also important for roasters. The more stable and consistent the temperature inside the machine is, the more consistent the roast profile will be.

“Stronghold’s X-Series roasters include a ceramic band heater around the drum system,” Alex tells me. “Because of this feature, the roaster can actively and purposefully control the temperature inside of the drum, ultimately allowing for more control over heat retention and dissipation.”

Installation is also a factor to consider. With gas-powered machines, roasters need to make sure they have a gas line ready, or get a permit to fit one if they don’t.

However, with electric roasters, installation is significantly more straightforward.

“Of course, with any large piece of equipment, you need to account for the size of the space [to make sure it fits],” Alex says. “But with an electric roaster like the S9X, you don’t need to account for a gas supply – just a stable source of electricity.”

What are the other benefits of using electric roasters?

Besides having more control over heat transfer, electric roasters boast a number of other benefits. This includes a number of cutting-edge features, such as AI-powered technology and other automated systems.

For instance, Stronghold’s S9X X-Lens temperature sensor improves the consistency and accuracy of various different roast profiles by measuring and recording bean temperature, rather than air or drum temperature.

“You can roast a full 8kg batch to maximise your output with no compromise on quality,” Alex explains. “Moreover, Stronghold’s Square platform means you can manage and share roast profiles with different roasters who also use Stronghold machines.

“Because of its user-friendly interface, the S9X can be used by a range of coffee professionals,” he adds. “World Roasting Champions work with our machines, as well as less experienced roasters.”

Amir agrees, saying “The S9X’s AI technology makes it easier to operate, and the precision in making adjustments on this machine are much more accurate than with gas-powered roasters.

“You can achieve quality and consistent results with every batch,” he adds.

Ultimately, with the increasing reliance on technology when using electric machines, roasters are able to diversify and experiment with roast profiles.

“The increased flexibility with different heat transfer combinations allows roasters to be more versatile than ever before,” Alex concludes.

It’s clear to see why more and more roasters are switching to electric machines. Along with natural gas prices and a push to cut carbon emissions, more roasters are also looking to regain control over a range of different variables to get the best from their coffee.

It’s safe to say that in the years to come, we will more than likely see the uptake of electric roasters increase. Just how the technology will continue to develop, however, remains to be seen.

Enjoyed this? Then read our article on how to ensure batch-to-batch consistency when roasting coffee.

Photo credits: Stronghold, Kühne Kaffee

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For coffee roasters, software is mainly aimed at two things: automating parts of the roasting process and giving them more control over a wider range of data points. In essence, this equips them to better optimise workflow, streamline operations, and improve quality control.

But how straightforward is it for roasters to implement new software into their operations, and what are the factors they need to consider when doing so?

To find out, I spoke to two coffee professionals. Read on to learn more about what they had to say.

You may also like our article exploring AI in coffee roasting.

Automation across the board

Over the past few years, it has become increasingly common to use software and data collection systems in roasteries. 

While implementing software can help roasters automate production roasts and spend more time on other areas of their business, data collection allows them to analyse and manage a wider range of variables which they can use to manage their roast profiles. 

However, this hasn’t always been the case. Prior to this shift towards more automation, many roasters had to account for people closely managing each batch.

As far as data is concerned, we now have greater access to a wider range of variables. For example, head roasters have traditionally had to carefully evaluate the characteristics of green coffee to determine the optimal roasting parameters, such as when first crack should occur or how long the total roast time should be.

Throughout the roasting process, roasters also had to keep a close eye on a number of variables themselves. This has historically included changes to bean colour and aroma, temperature fluctuations, and listening for the audible cues of first and second crack.

These are important variables that roasters need to account for when developing roast profiles, so in order to maintain consistency in their roast profiles, they need to collect data. With limited data collection software available, roasters would often keep handwritten notebooks.

However, with automation becoming increasingly prominent, more and more coffee professionals are choosing to implement new technologies and software across their roasteries

What software should you use to manage your roastery?

Today, there are many different types of software available for roasteries, including programmes which monitor and guide roast profiles, as well as those which predict when first crack will occur.

However, deciding which specific piece of software to use will depend on a roaster’s needs. Larger roasters will have different technical requirements than smaller roasters, for instance, and specialty coffee roasters will likely require software more focused on quality control than commercial brands which are more renowned for their output.

Inventory management

Daniel Mendoza is the North American Sales Manager at Cropster, a roasting software company. 

He tells me that inventory management systems are generally the first thing he recommends to roasters.

“Some roasters record all their data on paper, which can mean that their inventories are less organised,” he says. “So one of the first steps towards using more data collection systems for these roasters is inventory software.”

Moreover, many platforms designed to manage coffee roasteries have an inventory management function for tracking green and roasted coffee stock levels. Not only does this help to preserve coffee freshness, it also allows roasters to gain a better understanding of which coffees are more or less popular with customers. 

Daniel explains that most roasting software suites collect a range of data points. These include sample roast profiles, physical analysis of green and roasted beans, and optimal roast profiles, which help roasters remain informed when tracking stock levels or looking for new green coffee.

“When a roaster buys coffee, [the software can store all the relevant data points] for as long as necessary,” he says. “So instead of relying on paperwork or emails, all the information is now stored in one place.”

Time between roasting batches of coffee

Another area where software can benefit roasters is time spent between roasts, or “Between Batch Protocol” (BBP). This refers to all of the actions which take place between the end of a batch and the beginning of a new one.

Before attempting to implement roasting software, Daniel suggests that roasters fully understand each step of their process.

Many roasters follow their own BBP procedures, but it can be difficult for them to know if they are using this time as efficiently as possible.

“A lot of roasters don’t know how their time is spent between batches,” Daniel tells me. “There is no standard protocol in the coffee industry because each roaster defines their own procedure.”

“When roasters record the length of time in BBP, they may find that they are spending five or six minutes between roasts,” he says.

“In my experience, a three minute wait between batches is too long,” he adds. “However, a two minute wait between batches is more ideal because then a roaster only has [a total of] ten minutes of BBP per hour.

“Lorings, for example, are able to have a one-and-a-half minute wait between batches, which means you can do five batches an hour when at full capacity,” he continues.

Managing roast profiles

It’s no understatement that profiling is a key part of any coffee roasting business. As such, software which can support roast profiling and guide production roasts along specific curves are indispensable for many businesses.

A roast curve is a graph which indicates how temperature changes during the roasting process. Many roasters believe the “S-curve” to be a more traditional and straightforward roast curve, which results in a medium roast profile. 

While the S-curve can be a great starting point for less experienced coffee professionals, other roasters may want to develop their own more advanced roast curves. To do so, roasters can analyse a curve and adjust specific variables (such as temperature and airflow) at specific points to slightly tweak the end result.

While this can be done without the use of technology, software can help roasters to design new roast profiles, as well as automating production roasting according to a specific profile. Moreover, software can automatically track the progress of a roast over a set period of time, as well as being able to control the roast variables according to a preset curve. 

However, Daniel emphasises that the type of roaster you use will determine how compatible it is with specific software systems

“We have a customer in Canada who has a second or third-generation roaster,” he says. “They wanted to start using profiling software, but their Probat machine isn’t compatible with Cropster’s programmes.

“They can’t afford a new machine, so they have to focus on using software for inventory and quality purposes without changing the way they roast their coffee,” he adds.

Although it is possible to use roasting software on older equipment, this can be a difficult and risky task. Implementing software on an older roaster can significantly change commonly used roast profiles. For example, it may mean that roast profiles are lighter than usual, which some roasters may not be used to.

Ultimately, these changes could impact a roastery’s branding – potentially turning some loyal clients away – so careful consideration of using software on older equipment is critical.

How can roasting software improve consistency and quality?

For many roasters, adding roasting software to their setup can help them identify any areas of inconsistency – allowing them to improve coffee quality.

John Simonian is the owner of two-time Good Food Awards winner Beanstock Coffee Roasters in Eastham, Massachusetts in the US. He tells me he started using roasting software around three years ago.

“[Before we started using roasting software], we were roasting mostly on a Probat L-12,” he explains. “On this model, the temperature is controlled using a knob on a little metal pole which you pull out and push in to control the flame.

“The pole is marked and divided into ten sections,” he adds. “At different points during the roasting process, you need to move to different sections of the pole. For example, one minute and 26 seconds into the roast, you would need to move the pole to marker number two.”

Reflecting on this process, John says the team were unable to effectively collect and store data which could help them improve their roast profiles. 

“For instance, if the ‘rate of rise’ (RoR) changed, or the exhaust temperature or environmental temperature increased, we wouldn’t know,” he tells me. “When we first implemented roasting software on our machine, we didn’t realise that our central heating line that was next to the gas line for the roasters was affecting our coffee.”

Essentially, roasting software can identify areas which roasters may not notice themselves. John says that by using software, he and his team were able to spot these issues earlier on than beforehand.

How can implementing software affect how you train your staff?

One of the biggest challenges for more established roasters is effectively and efficiently passing on their coffee skills and knowledge to newer team members.

However, thanks to the sheer amount of data points coffee roasters can now have at their fingertips, this process should theoretically be much easier.

Roasters can then develop their training programmes by leaning on their software, and use it as a tool to educate less experienced staff about the process of roasting.

“For me, the increased opportunity for training is a big advantage,” John says. “Roasting software provides us with so much more information that wasn’t available beforehand.

“You can now go back to the cupping table and review roast profiles,” he adds. “You will be able to taste the difference if you make any changes.”

Ultimately, this will not only optimise a roaster’s operations, it will also help to improve overall coffee quality.

Considering the challenges

Despite the clear advantages, roasters can still face challenges when implementing new software.

Introducing staff to new software and data systems could be complicated, as it’s just one of many things that roasters need to consider when it comes to optimising operations and increasing coffee quality.

Moreover, some roastery staff may find it difficult to understand how to operate new software – especially when using more than one new system or platform at a time.

In turn, roasters need to carefully consider which software best suits their needs.

There’s no denying that using more advanced roasting software has its advantages, whether that’s increasing consistency, winning back more time to sell coffee and handle other responsibilities, or giving you the tools to profile new coffees with more precision than ever before.

However, precisely which programmes or software suites might be suitable for a roastery will depend on a number of factors – from your batch capacity and business size to your target audience.

Enjoyed this? Then try our article exploring automation in coffee roasting.

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However, as with any other piece of precise industrial equipment, consistency can degrade over time with regular use. So, what can roasters do to keep their machines consistent? And how should they be maintained? 

To answer these questions and learn more, I spoke to two coffee roasters and a specialist service technician. Read on to find out what they told me.

You might also like our article on using the right ventilation system for your roaster.

Why is consistency important?

For roasters, there is understandably a focus on developing a roast profile for each new coffee they bring in. A “perfect” profile will unlock the flavours hidden within the green beans, allowing the coffee’s best qualities to shine through, whatever they may be.

Once this perfect profile is developed, however, the roaster faces their next challenge: replicating it consistently from batch to batch. 

Luis Fernando Velez is the owner of Amor Perfecto, an award-winning roastery based in Bogota, Colombia. He tells me that it’s incredibly important that roasting technology returns on the investment by producing consistent results for customers. 

“A few weeks ago, a Korean company ordered a huge amount of coffee from us,” Luis says. “They needed 16,000kg of coffee, and we roasted it in five days. We had no issue with the machines [and their consistency].”

Ultimately, having a reliable and consistent roaster allows businesses to respond to these kinds of large orders. It allows them to move quickly, removing any bottlenecks from the process of roasting coffee itself.

Luis also explains that a roaster has an obligation to deliver consistency not just for the customer, but also for the farmers they source from. Roasting coffee to a consistently high degree of quality upholds the producer’s reputation just as it does the roaster’s. 

“[This is why we] put the name of the coffee grower on the bag,” Luis says. “I find it interesting, as in the past, many roasters wouldn’t do that. They were afraid their competitors would go and buy the coffee too.

“However, my philosophy is that if [another roaster] goes to the farmer and buys the coffee, I’ve done my job correctly.”

So, what can go wrong with your roaster?

Over time, regular use of a roaster will naturally cause parts of it to wear down and fail. Machines can also get “clogged”, generally thanks to various buildups that occur during the roast (chaff and coffee oils, for instance). 

Any kind of damage or failure due to continuous use can, over time, affect batch consistency – so keeping your roaster clean and well-maintained is certainly in your best interest.

Joe Thill is a roaster technician at Usonian Systems. He says: “Roasters have what we call ‘wear parts’; expendable components that are generally meant to be fairly interchangeable and can be relatively easily replaced.

“These wear parts prevent wear on other parts of the roaster, which are either more expensive or more difficult to replace – often both.”

However, by understanding which parts of your roaster are designed as “wear parts”, you can target your maintenance, prolong their life, and protect your machine in the long term. This, consequently, will help you to be more consistent. 

“One area where I see lots of buildup is the cooling fan assembly,” Joe says. “All of the ducting attached to the cooling fan is especially prone to a buildup of coffee oil. This condenses on the inside of the duct tubes, and forms a sludge. Over time, this can lead to decreased efficiency in the cooling fan.”

The cooling fan is an essential part of a roaster, as it helps to precisely control and manage temperature during the roast. As the cooling fan becomes less efficient and precise, accurately recreating roast profiles will become more and more difficult.

Joe also notes that how you roast and the profiles you use can actually affect how quickly these buildups occur. With darker roasts, more oil migrates to the surface of the bean as the sugars develop, meaning more escapes into the roaster itself. 

“Roasters that are regularly producing darker roasts for multiple hours a day are definitely going to see an increased buildup of that coffee sludge,” Joe says. “To address it, you can just blow out fan motor housing with a can of compressed air or something. That’s how we clean those fan blades.”

Batch size matters

Another detail to keep in mind for machine maintenance is the batch size of your roaster. As a roasting business grows, it will naturally require larger machines to meet increasing demand. 

A higher batch size can also help increase consistency, however. Roasting two 10kg batches instead of one 20kg allows more room for deviation. 

In a wholesale setting, however, Joe explains that larger roasters are more likely to be used for darker espresso roasts rather than filter roasts (purely because of demand). Consequently, in his experience, this means larger roasters tend to suffer more from these buildups.

“Even though high-capacity roasters have a larger tubing size for their venting to accommodate, we generally see that darker roasts are more frequent and more prevalent in larger roasters,” Joe says. “They also tend to run more often and have higher workloads, [causing more of a buildup].”

Ultimately, while investing in larger capacity roasters helps to make your roasts more consistent, it also makes regular maintenance even more important.

How can roasters keep their equipment consistent?

Some parts of a roaster will naturally wear down over time with regular use. David Fullerton is the owner of Acoustic Java, a roastery based in Worcester, Massachusetts. He tells me that he uses a Loring S35 Kestrel, but notes that there are specific components he keeps an eye on in particular.

“So far, it’s just the non-steel parts,” he says. “Components such as the edges of the cooling bin paddle fins and the hose connecting the rolling loader bin cart to the roaster hopper.”

He says that a regular maintenance schedule can help you maintain these components – the “wear parts”, as Joe calls them.

David says: “There are some daily maintenance tasks [you can take on], such as emptying the chaff barrel. After that, of course, there are weekly, monthly, and annual tasks, from cleaning the cyclone spray nozzle to checking the exhaust stacks and cleaning as needed.” 

However, roasters should be wary that depending on the age of their roaster, a different approach to keeping things consistent should be taken. For instance, modern Loring roasters rely on airflow to roast the beans, as opposed to classic gas drum roasters. This means they require a different approach to maintenance.

Joe says that ensuring consistency with a Loring starts with making sure airflow control is as precise as it can be. “The key is blowing out the fan motor housing with compressed air (or something similar). A lot of the time, that can dramatically increase efficiency in all of your fans. 

“In a Loring roaster, you have a couple of different motors controlling a couple of different fans throughout the roaster. Making sure those parts run at peak efficiency is important for longevity… it’s the most important part of the roaster, and the most expensive component to replace.”

Other steps

However, a regular in-house maintenance routine alone may not help you maximise roster consistency. There will naturally be times throughout your roaster’s life cycle where something extra is needed.

For instance, Joe tells me that Usonian offers yearly and bi-yearly service programmes to ensure their customers’ machines are always functioning at the optimum level. They offer a technical service package with an on-site visit from a skilled, experienced technician.

Joe says: “This includes identifying a few different parameters and taking measurements, things along those lines. We have a basic standardised checklist of things to go through, such as paddle measurements within the drum.”

Taking these measurements allows the service professional to monitor any wear or degradation over time, comparing it to figures from previous years to understand how the machine is changing.

However, it’s not just a mechanical or technical service that you should focus on. David also notes that software upgrades can help your machine stay consistent from batch to batch, too.

“Usonian recently upgraded our machine with ‘turbo burner’ software. They facilitated the entire process with us, in collaboration with Loring.

“Thanks to careful planning, we experienced no downtime, and our few follow-up operational questions were addressed by the technician as they arose following the successful installation.” 

Finally, having a specialist on-hand for any more immediate issues can help maintain consistency if your roaster suddenly encounters dramatic difficulties. For instance, Luis tells me that remote support from Usonian helped with a major order. 

“​​Before [started on a contract that required us to roast] 1,000kg over five days, [our larger roaster stopped working at 100% power]. We called Usonian, and received [everything we needed remotely] to recalibrate the burner. That was it.

“All it took was a couple of hours on the morning before we started roasting, and we were ready.”

Batch consistency should be a key priority for any specialty coffee roaster, but maintaining it over time is easier said than done. However, the more you understand about the inner workings of your machine, the better equipped you will be to understand why consistency changes, and what you can do to help.

Ultimately, creating daily, weekly, and monthly maintenance schedules will be key. However, in the long term, partnering with a technical specialist and making sure your machine is regularly serviced is invaluable. 

Enjoyed this? Then you’ll like this article on upgrading your coffee roasting space.

Photo credits: Usonian Systems

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The fluid bed roaster has technically been around since the 1970s, but has become more popular in recent years. It heats the beans in a fundamentally different way, leading to some key differences in the roast.

To learn more, I spoke with a roaster and two manufacturers. Read on to find out what they told me. 

You might also like our guide to airflow in roasting and how you can control it.

A history & guide to fluid bed roasters

The technology for fluid bed roasters has been around since the early 1970s. In the 1960s, chemical engineer Michael Sivetz realised after working in a polyurethane plant that he could adapt a process used for drying magnesium pellets to roast coffee, thus inventing fluid bed roasting.

For years, fluid bed roasters were consequently referred to as “Sivetz roasters”. And while they attracted a small following in the 1970s, they didn’t really become popular until much later.

The difference between drum and fluid bed roasting is simple. In a drum roaster, the metal drum is heated, which then transfers heat to the beans. However, with a fluid bed roaster, the air is heated first and then blown through the roaster bed, eliminating the need for a heated drum.

Tim Monson is the Head Roaster & CEO at The Monsoon Roastery in Springfield, Massachusetts. He says: “Fluid bed roasting uses convection heat, rather than conduction or induction. 

“In a typical drum roaster, whether it is electric or gas, you have a rotating drum with heat coming from underneath it; sometimes it’s direct, sometimes indirect,” he continues. “In a fluid bed roaster, you’re creating your heat and your airflow from the bottom. 

“This keeps the beans in a constant rotation, so that they’re not actually roasting on a surface; they’re being roasted from the air and the pressure moving in the chamber.” 

As the hot air flows through the roaster, the force lifts the beans into the air, causing them to float. This effectively means the coffee beans are resting on a “bed” of heated air, which is where fluid bed roasting gets its name from.

Ken Lathrop is the owner of Coffee Crafters, based in Post Falls, Idaho. He notes that after the beans are roasted on this bed of heated air, they still need to be cooled externally, even though it might look like this can take place inside the machine.

“We tried to do that in the beginning, and it didn’t work,” he explains. “If you do a good job of insulating your heat chamber, it holds the energy in, so when you shut it off, it’s still roasting.  

“What we do is we release the beans into a separate chamber and then flash cool them. A ten-pound load will cool in about 90 seconds,” Ken tells me. “We direct a lot of air into the bean cooler to suck the heat out of the beans as quickly as possible.”

Gökhan Mithat Karakundakoglu is an Export Manager and SCA Authorised Trainer at Toper, a Turkish roaster manufacturer. He says that Toper has been producing roasters since 1954, but has only recently started producing fluid bed roasters.

“There has been a growth in demand from customers who wanted to start a more boutique style of coffee company,” Gökhan says. “They [often] feel that the appearance of the machine is more stylish than a classic drum roaster.

“Our fluid bed roasters only run on electrical power, which is useful for roasters who don’t have a direct gas supply.” 

What are the key differences in flavour when roasting on fluid bed and drum roasters?

For starters, Tim says that certain origins and processing methods can really shine on a fluid bed roaster.

“I find that a lot of naturally processed coffees tend to really pop with the direct convection,” he explains. “They seem a little bit cleaner, and it helps propel some of the sweetness.”

However, Gökhan notes that testing Toper’s fluid bed models led to both positive and negative feedback. “We have found that some fluid bed roasting results end up a little dry compared to a drum roaster,“ he tells me. 

With drum roasters, roastmasters monitor the amount of air entering and leaving the roaster to maintain a certain moisture level for specialty coffee. If coffee is roasted beyond a certain moisture level, becoming “dry”, it will lose complexity and its more subtle flavours.

However, because fluid bed roasters only use air to heat the coffee, rather than residual heat from the drum, moisture loss is more of a concern.

If too much moisture is lost early in the roast, the beans can end up being flat tasting once roasted.

However, Gökhan also notes: “Because you are only using hot air to roast the beans, [it is easier] to prevent tipping (also known as scorching), which can happen easily in a drum roaster with certain beans.”

Tim also says that while roasters might assume roast curves and profiles are fundamentally different on drum and fluid bed roasters, they are actually deceptively similar. 

“Fluid bed roast curves are within similar parameters for classic roast curves,” he notes. “However, it depends on the bean; the convection means factors like how high it was grown and the processing [play a part].

“Because you’re throwing heat directly onto the bean, you need to be a little bit more gentle with your rate of rise to avoid scorching.”

Ken adds that fluid bed roasters can be used for both light and dark roasts, but notes that they’re excellent for more developed profiles. “One of our customers would tell you is that he likes dark roasts better out of a fluid bed roaster because you can take it to a darker roast profile and cool it more quickly. 

“At some point when you’re roasting, you’ll hit that breakpoint where you start drying the oils and sugar down in the beans with a drum roaster. Fluid roasters are really good at doing a dark roast.”

Energy consumption: Fluid bed vs drum

Understandably, energy efficiency is a key priority in today’s coffee sector. Consumers are increasingly looking for more responsible and sustainable products. In addition, technology with a lower carbon footprint and less energy use will be cheaper for a roaster to maintain. So, are fluid bed roasters more energy efficient?

The answer is that it depends on the machine. Ken says that at Coffee Crafters, energy efficiency is a key focus for the roasters they manufacture. However, historically, this has not been the case. 

“The original Michael Sivetz design required a huge 350,000 BTUs of heat and a massive amount of air,” he says. “However, we’ve done extensive research in the last seven years. We’ve started raising the air pressure in the heating chamber, allowing us to [roast] larger loads with a lower amount of air. 

“Our new 25lb roasters are probably going to end up needing less than 100,000 BTUs of heat,” he adds. “We’re trying to achieve about 3,500 BTUs per pound of green coffee, which would actually be more efficient than a gas roaster.”

Tim also notes that much like drum roasters, fluid bed roasters can be fully electric, and says that he has the option to choose where his electricity comes from.

“I source my electricity entirely from renewable energy sources,” he tells me. “This means that we’re not burning fossil fuels and that the energy we’re getting comes from a combination of wind and solar.”

As well as helping reduce the company’s carbon footprint, this may also make it more attractive for consumers who exercise greater environmental awareness in their buying habits.

What are the advantages?

For many, the advantages of a fluid bed roaster over a conventional drum roaster come down to two main factors: cost and ease of use. These are particularly important for roasters at the beginning of their journey.

Tim tells me that he started his journey at Monsoon on multiple small-batch home machines. He says that fluid bed roasters were more affordable, and helped him to scale up and roast larger batches while still maintaining quality.

“I actually went with the fluid bed roaster as a little bit more of an economic point,” Tim explains. “I found myself having to relearn a little bit of what I was doing, but it was actually closer to what I started roasting with, the popcorn popper right at the beginning.”

Ken adds that the ease of use is a key point for most Coffee Crafters customers. “One of the advantages is in the simplicity,” Ken explains. “Some 75% of our customers have little to no roasting experience when they start their business.”

Given that fluid bed and drum roasters also offer the same markers for development throughout the roast – and that traditional curves and profiles are at least somewhat similar – it can also be easy for more experienced roasters to make the switch.

Ken also adds that the simplicity isn’t just in the roasting, explaining that it’s “simplicity in operation and simplicity in maintenance”. Fluid bed roasters are often designed in a much more accessible way, making them easier to repair if something does go wrong.

“Our roasters only have one moving part, which is the loft motor that locks the beans,” Ken says. “Everything else is solid-state electric, meaning [the parts are] really durable, easy to work on, and easy to install. We designed them to be installed in home roasting environments, and certified them for food safety and coffee shops, but people can install these in their garage or their basement.”

While fluid bed roasters are by no means everyone’s first choice and perhaps less viable in a commercial setting where volume is the main priority, they certainly have their place in coffee roasting and are becoming more popular. 

There’s no doubt that drum roasters will remain mainstream, but fluid bed roasters can be an excellent and often more economically viable option for roasters who want something more affordable and compact. However, whether or not they will become more popular in the years to come remains to be seen.

Enjoyed this? Then try our article on defining your roast profile.

Photo credits: Coffee Crafters, The Monsoon Roastery

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And despite an increasing sector-wide focus on sourcing ethical, organic, and eco-friendly coffee, the environmental impact of other parts of the supply chain can sometimes be overlooked. This includes coffee roasting itself.

However, in the last few years, there has been a move towards better energy efficiency and more sustainable technology in roasters. To learn more about this, I spoke to Dennis Vogel from Loring, and Ram Evgi from Coffee-Tech Engineering. Read on to find out what they told me.

You might also like our article on improving sustainability in the roastery.

What are the environmental issues for roasters?

There are a number of environmental concerns about coffee roasting. Along with the carbon emissions and other hazardous gases released as a byproduct of the fuel combustion in the roaster, coffee roasting also generates smoke and other harmful particulates. These emissions can be dangerous for those operating or working near the roaster, as well as contributing to greenhouse gas pollution.

Ram Evgi is the CEO and founder of Coffee-Tech Engineering, based in Israel. “The damage to the environment is caused by what we pull out of the duct,” he tells me. 

“However, the more immediate damage can happen to the roastmaster themselves, and anything in the surrounding area that is exposed.”

Across the coffee sector, brands like Coffee-Tech Engineering and roaster manufacturers have been monitoring the levels of these emissions for some time. Dennis Vogel is the Director of Marketing and Sales at Loring, a roaster manufacturer headquartered in California.

Dennis says: “Traditional roasters produce visible emissions (i.e. smoke), odours, and pollutants such as nitrogen oxide, carbon monoxide, volatile organic compounds, and carbon dioxide, unless a filtering system or external afterburner is used.

“In addition, afterburners also consume fuel, which is traditionally natural gas or liquefied petroleum gas (typically propane).”

What causes these issues?

To put it simply, there is something of a “lag time” when it comes to innovation in roaster technology. Moving through processes like design, proof of concept, and manufacture to distribution and widespread use can take years.

Many specialty coffee roasters started out using (and still use) machines that were originally designed in the mid-20th century. Many of these original machines have since been refurbished, upgraded, or even re-released to meet new demands for quality, consistency, batch size, and aesthetic quality. 

However, at the time when these machines were initially designed, climate change and biodiversity were arguably not that high on the global agenda. As such, emissions regulations would have been much more relaxed, and the environmental impact of the roaster would not have been a priority.

Ram also says that there are certain structural “design flaws“ that are responsible for most of the environmental concerns in coffee roasting.

“An important issue which is regularly overlooked is the structure of the machine itself,” he says. “This is related to many different aspects, including user safety, efficiency, repeatability, and accuracy.

“Most machines up to 100kg batch capacity still utilise open-structure atmospheric drum housing. This means that the burner is operating within the same atmosphere as the room, aspirating (drawing in) the preliminary air by itself, rather than in a sealed structure with sub-atmospheric conditions.

“This effectively means that every emission coming out of the burner is also spread into the roasting space.”

In comparison, Ram says that contemporary “greener” roasters (such as those used by Coffee-Tech Engineering) can isolate these emissions within the machine. This protects the environment around the roaster (including the operator) and gives the machine more time to break down these harmful gases. This effectively “cleans” the emissions.

This isolation process also has the secondary benefit of absorbing the thermal energy in the emitted air to keep the machine heated. This improves energy efficiency for continuous roasting, making the roaster even more sustainable.

Can you “fix” your roaster?

Most roasters are trained on a certain model or machine through years of practice. Each roaster is different, and changing models can render your finely-tweaked pre-recorded roast profiles useless if they don’t translate properly to a shiny new machine.

Furthermore, roasters generally represent a significant capital outlay for small and medium businesses. A good commercial roaster can be difficult to find for anything under US $10,000. For those looking at cutting-edge environmentally-friendly roasting tech, it’s likely to be much more costly.

As such, for many roasters, the first port of call is fixing an existing machine, rather than buying a new one. Despite this, Ram says that converting your roaster to make it more “green” is easier said than done, especially for older models.

“It’s not always worth the effort,” Ram explains. “Most traditional machines use open atmospheric drum housing (which releases the emissions into the room, as mentioned previously) and no real combustion chamber. This means it will keep on sharing anything happening inside the machine with the room it sits in.

“The burner can be upgraded or changed, as with many other parts, but the quality of the machine is not so much down to the accessories. It lies more in its initial design, and in its organic structure.”

Ram uses the analogy of buying a new car to explain his point: “Adding anti-lock braking or modern tyres will help, but there is nothing better than modern suspension geometry and optimal weight distribution.”

A new generation of roasters

In today’s sector, the environmental impact of the coffee supply chain is rightly becoming a more prominent issue. Forbes research shows that consumers are more likely to be loyal to sustainable brands. As such, roasters who make a commitment to sustainability are more likely to see brand loyalty from both retail and wholesale customers.

This has sparked a movement towards the design and manufacture of several energy-efficient or “green” roasters over the past few years. However, the technology used in these newer designs isn’t necessarily new or revolutionary; the way it is being used is where the innovation lies.

Dennis tells me that Loring has recognised this challenge from customer feedback. “The feedback we’ve received from our customers consistently indicates that environmental sustainability and air quality are among the top challenges they face,” he says. “Our customers value environmental responsibility too, meaning that lower emissions and fossil fuel consumption lead them to select our roasters.”

He says that there’s a specific design Loring has used to create a more environmentally-friendly machine.

“Our roasters utilise a single burner to both roast coffee and incinerate the smoke created during the roasting process,” he says. “This essentially eliminates the need for an external afterburner.

“In addition, by recirculating the air through our closed-loop system, less energy is required to heat the already-warm air to ideal roasting temperatures, while traditional systems must use more energy to [do so].”

However, even though newer models are becoming more prominent, Ram says the benefits aren’t as high a priority for roasters as some might think. He also says that the figures aren’t always precise, meaning that it can be difficult to get customers to acknowledge the financial benefit of a more energy-efficient roaster.

“It isn’t simple to predict gas consumptions from the brochure, and not easy at all to measure them,” he says. “Additionally, while some machines are smoke-free thanks to their internal gas recirculation system, this is not a new development. It was invented by Vittoria [as early as] the 1980s, and has been adopted by few other companies [since then].”

While traditional roasters can be upgraded to become more energy-efficient, it seems like the full structure of older models is more of an issue than particular components or features. Add to that the fact that roasters are significant investments for any individual or business, and it becomes clear that the choice to use a “green” roaster isn’t always a simple one.

In spite of this, the number of energy-efficient roasters emerging on the market is a step in the right direction. The lag time and the investment required means we may only see the benefits of this switch in the long term, but the innovation is there. While it’s not going to happen overnight, greener coffee roasting is a possibility – and it can save roasters money while shrinking their carbon footprint.

Enjoyed this? Then read our article on how you can consume coffee in a more environmentally responsible way.

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Photo credits: Coffee-Tech Engineering

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However, when getting started, one of the biggest decisions you need to make will be choosing a machine. Commercial coffee roasters will choose machines based on a number of factors, but in a coffee shop setting, it is a different challenge altogether.

There is a whole range of machines out there to choose from, each with their own styles, functions, and features. As such, finding the right roaster for your coffee shop is a challenge. To get some tips, I spoke with Michael Caro from Nook Bakery & Coffee Bar and Coffee and Kaapo Paavolainen from One Day Coffee Co. Read on to find out what they said.

You might also like our guide on how to launch your own specialty coffee shop.

Why would a coffee shop start roasting their own coffee?

In the beginning, most coffee shops will source their beans from wholesale roasters.

This can be especially helpful in the first few weeks and months. As you’re finding your feet in a new coffee shop, a reliable source of delicious roasted coffee will provide stability. Additionally, if you partner with a high-profile or recognisable roaster, customers may even be more likely to enter your coffee shop.

However, roasting coffee in-house can massively improve profitability if you do it at scale. After the initial upfront investment in a roaster, your supply costs can drop as you buy green coffee and roast it yourself.

Michael Caro is the owner of Nook Bakery & Coffee Bar in Philadelphia, Pennsylvania. He says that roasting coffee in-house “saves [him] a lot of money”.

It will also make you more precise. Roasting to meet the exact amount of coffee you sell will make sure you are less likely to ever be under or oversupplied.

Michael adds that sourcing and roasting your own coffee doesn’t just give you the chance to offer people new flavours. It also opens up a whole world of possibilities by connecting you to the people and stories behind each cup. “We are just that much closer to the source of the coffee,” he says.

“We can discuss everything directly with importers and farmers, everything from growing conditions to processing methods. That insight and knowledge makes it so much more interesting.”

With this insight, you will be better equipped than ever to not just meet customers’ needs, but also bring them new, exciting flavours that can set you apart from the competition. 

“[I got into] developing custom blends to match our customers tastes and to roast [each coffee] exactly the way I want it,” Michael says. “Obviously my way isn’t the only way, but it’s how I prefer it.”

Furthermore, once you’re more experienced at roasting, you can take the opportunity to package and sell roasted coffee as an additional income stream. 

This is especially relevant during the pandemic. Many coffee shops across the world have been forced to close or limit operations in some capacity. At the same time, online sales of roasted coffee have skyrocketed.

Michael says that thanks to the increase in online orders, the higher average customer spend on roasted coffee has mitigated his overall loss of transaction volume by 40% to 45%.

Tips for choosing the right roaster

So, now that you’ve decided to roast your own coffee, you need to choose a machine. There are a few factors to keep in mind when doing so.

However, it might also benefit you to speak to roasting experts and other coffee professionals if you have any questions. The next Roastrum webinar, which is set to take place on Friday, February 26, 2021, will focus on the “transformation” from coffee shop to roastery. You can sign up here.

Consider your space

First tip: think about the space you’re operating in. Many independent coffee shops are set in smaller premises where floor space may be limited for a number of reasons. 

Typically, roasting requires a significant amount of space. Roasters themselves often take up a large amount of floor space (which varies based on capacity) but beyond that, you will need a dedicated area for storing and packaging beans, too.

Additionally, keep your roaster out of high-traffic areas. Consider how your baristas will be moving behind the bar as they pull shots, steam milk, and speak to customers – and keep your roaster out of their way.

Michael explains the benefits of choosing a compact roaster. “[We use a] Stronghold S7 Pro, a compact commercial roaster with a maximum capacity of 850g (1.87lb),” he says. “It can comfortably sit on the surface behind your coffee bar, or be stashed away in a side room.”

Ease of use

Roasting is a complex chemical process. It can take years of practice to fully understand, and even then, there’s no guarantee that you’ll achieve consistent results. 

If you’re just starting to roast your own beans, it can be good to choose a roaster that is more accessible. While there aren’t too many roasters on the market that are aimed at those with less experience, they do exist.

Michael says that he had no prior experience when he started roasting his own coffee. He says: “After one demonstration outlining the roaster’s basic operation, I set it up on a mobile cart near our front door.

“Over the course of several nights and weekends, I roasted, tasted the results, and repeated… roasting and tasting, roasting and tasting, progressively getting better.  

He adds that no matter which roaster you choose, it’s important to recognise that roasting is a process of continuous improvement. 

“Trial and error may not seem like the most efficient learning process, but it’s a very effective teacher in the long run,” he says. “Paying close attention to your work, looking closely at the results, and listening to feedback from others can help make that learning curve less steep.”

Kaapo Paavolainen is the founder of One Day Coffee Co. in Helsinki, Finland. As a more experienced roaster, he says the experience of using the S7 Pro “feels like you’re driving a Tesla”.

Kaapo says that the S7 Pro is fully electric. He notes that with traditional gas-powered roasters, there is “latency” because of “gas management, the valves, or the flame heating the drum or a fluid bed of air”.

“[However], with the Stronghold S7 Pro, all your controls are second-by-second,” he says. “It really feels like you ‘push the pedal’ and it just goes.

“It is interesting, because it takes a while to get used to it. Once you do, however, you start to appreciate the finer control that you have with electricity.”

Keep labour costs in mind

Roasting will require a financial investment. As well as the money you spend on the roaster itself, you have to keep in mind that a member of staff will need to spend time operating the machine.

For some coffee shops, this will be a member of staff who already works there. Others may find they need to hire somebody who has more roasting experience, or even invest in upskilling an existing team member. Either way, this represents a cost in some capacity, whether it’s in terms of existing staff time or a new hire.

Altogether, this means that coffee shop owners should look for roasters that can help them save time (and therefore money) in the long term.

One of these is the ever-popular profile “auto-replication” feature. On the Stronghold S7 Pro, for example, there is a proprietary profile replication algorithm.

This can record and replicate pre-existing roast profiles, meaning that the same flavours can be produced time and time again without the need for an operator to stand over the roaster.

This gives team members more freedom to multitask, rather than always requiring somebody to sit there and watch the beans through the roast. In turn, this leads to a more efficient team and lower operational costs.

Furthermore, in some coffee shops, it’s not uncommon for a single barista to be working alone on shift. If this is the case, it’s only more important that you look for an accessible roaster that can be programmed to work at least semi-autonomously.

“[Using the S7 Pro], I was roasting while also researching custom boxes, tissue paper designs, serving customers, and so on,” Michael says. “It’s wonderfully helpful in terms of being able to multitask without really messing up.”

Energy & the environment

Modern consumers are increasingly starting to demand that brands become environmentally sustainable. As such, operating in an energy-efficient way can influence the number of customers who visit your coffee shop, as well as your utility bills.

Roasting is an energy-intensive process, and most traditionally-designed roasters are fuelled by natural gases. However, in recent years, a greater number of fully-electric roasters have entered the market. As a long-term investment, an energy-efficient roaster can minimise your environmental impact and benefit your business in the long run.

Kaapo says that at One Day Coffee, he now operates a coffee roastery that is powered completely by renewable energy.

“The S7 Pro only used electricity, and here in Finland, we’re able to choose how our electricity is produced,” he says. “The electricity I’m utilising has been produced by wind and solar energy, which means that the energy I’m using for roasting is all renewable.

“I know it might just sound like a marketing gimmick, but it’s pretty amazing.” 

As with any investment in equipment, choosing a roaster for your coffee shop will require a lot of research. 

So, before you make a purchase, think long and hard about where you’ll put the machine, how it will affect barista workflow, who will manage it, and how it’ll affect your energy bills. Considering all of these factors will help you choose a roaster that’s right for your setting.

Enjoyed this? Then try our article on high-tech equipment in the coffee shop.

Photo credits: Nook Bakery & Coffee Bar, Stronghold

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Most manufacturers recommend that roasters don’t use a machine at full capacity. As a general rule, they recommend using about 75% of the listed capacity (depending on the manufacturer) to allow for consistent airflow through the roast.

You can even go down to 50% capacity or lower for sample roasting and profiling. However, doing so will mean you have to adjust the way in which you roast as you have much more space in the drum. 

Altogether, this mean’s that it’s important to take a balanced approach when deciding on the size of your roaster; too big can be just as detrimental as too small. For more insight, and to break down roasters into a few different size categories, I spoke to Neil Maree from Genio Roasters in Johannesburg, South Africa. Read on to find out what he said.  

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Picking The Right Size Is Important

Neil says that at Genio, customers are often unaware of the details they need to consider when buying a new roaster. “People often ask for the completely wrong size, or they ask about the price of all of our roasters,” he says. “To me, this points to a lack of knowledge and understanding about both their target market and their ability to sell.”

He says that while people often seek out larger roasters as a way of ensuring that they have the capacity to expand, it’s not that simple. “A lot of people have think they have to go for a large roaster in order to turn a profit. These people think that they need a giant machine just to roast coffee for the local community. 

“Ultimately, upscaling your operation is simple, as long as you have a buyer for the coffee. Being able to roast 5,000kg of coffee does not mean that you can sell 5,000kg. Start by selling 1kg, then 100kg, and then 500kg, and so on,” Neil explains. “Often, we find ourselves convincing people to go for smaller machines.”

However, this doesn’t mean there aren’t mistakes among people looking for smaller machines. Neil says: “On the other end, we’ve got people who think that they can buy a 1kg roaster and start a business from it.  

“It takes 15 minutes to roast a batch on a 1kg roaster, which will sell for maybe US $30. In order to make a salary as a business owner with that, you’d have to stand behind the machine for the entire day,” he explains. “This leaves you no time to sell! Roasting does not equal making money. Selling equals making money.”

To illustrate the time cost for using roasters of certain sizes, Neil compiled a set of models and forecasts for roasters of different skill levels that you can find here.

Sizes & Categories

For the purposes of this list, we’ve broken down commercial coffee roasters into six main categories by capacity: sample, small batch, small commercial, medium commercial, large commercial, and extra large commercial.

Sample Roaster (50g to 500g)

As the name suggests, the main focus of a sample roaster is to evaluate samples of a certain coffee before you commit to buying large volumes of it. 

While you can find exclusive and high-quality coffee roasted in small batches on sample roasters, they are not alone suitable for anyone looking to start a roastery at a large scale.

There is also a lot of overlap between craft and sample roasting at this range; many home roasters will naturally stick to a low minimum capacity if they are roasting coffee to solely be enjoyed at home. 

Small Batch Roaster (1kg to 3kg)

After sample roasters, the next step up for roasting coffee at any kind of commercial scale is a small batch roaster. These range in size from 1kg to around 3kg and are great for sample roasting in larger batches or identifying the right roast profile for a new coffee. 

These are a great option for micro roasters, as well as successful coffee shops looking to roast their own beans. Most coffee shops don’t sell more than 10kg of coffee in a day, but even if they do get close, a 1kg to 3kg roaster will be able to deliver that in a matter of hours.

For a café or a smaller existing coffee business, this is a good place to start. By starting small and being strategic about how much coffee you roast, you can build up a wholesale customer base steadily without the risky overheads of a more expensive roaster. 

Neil tells me that this was the target market for Genio’s smallest machine, the Genio 3 Micro Coffee Roaster, launching in December 2020. “With this, we wanted to focus on people who were ‘owner operators’; one or two-person businesses who roast and sell by themselves,” he says. 

“A 3kg roaster is the backbone of the owner-operated roasting industry.  You have enough capacity to really grow with a low enough capital outlay to be accessible to anyone with some savings and a passion for business.”

Small batch roasters also have their uses for larger roasteries, however. Many will keep a machine of this size on-hand to profile new coffees without wasting large quantities of fresh green coffee. These profiles can then be translated onto larger commercial machines to start roasting at scale.

However, it’s also important to note that your consistency will naturally decrease as you start roasting a greater number of batches. For example, roasting 600 batches in a 1kg machine will leave more room for error than, say, roasting 100 batches on a 6kg machine. Keep in mind that a lack of consistency could have an impact on customer retention.

Small Commercial Roaster (5kg to 15kg)

Commercial non-small batch roasters start at around 5kg. The next step up from a small batch roaster, these machines are more suited to teams looking to roast coffee at scale rather than small businesses or cafés looking to diversify.

“A 6kg roaster can roast up to two tonnes of coffee a month,” Neil tells me. “That’s a lot of coffee.” He notes, however, that despite this potential output, smaller-capacity commercial roasters are still quite versatile and can still be used to roast very small batches for profiling. 

Neil also warns against roasting to a machine’s maximum weekly or monthly output. “Roasting two tonnes of coffee on a 6kg machine is like driving 5,000 miles every month,” he says. “It is certainly possible, but you’d need to have a mechanic regularly carry out a major service on your car.”

Finally, Neil notes that a roaster of this size is a significant investment. For many up-and-coming roasters, he warns that a larger roaster could be bigger than the business needs. “Even if you can roast two tonnes of coffee a month, you need to think: who are you going to sell this coffee to?”

Medium Commercial Roaster (15kg to 30kg)

Machines with a batch size of around 15kg are most suited to existing roasting businesses that already have a solid base of customers. Many successful specialty coffee roasters will find that this is the biggest machine they will ever need.

Neil notes that many roasters find it tempting to sell their preexisting roaster to finance an expensive purchase, but warns against it. He says that he often sees this when people come to him to buy larger roasters, such as the Genio 15 or the Genio 30.

“Let’s say you have a 6kg roaster and you want to buy a larger roaster. I would say that you shouldn’t sell the 6kg roaster – that should become your backup. Mechanical faults do happen – things break.” At this point, with an established customer base, being left without a roaster could be catastrophic. 

Large Commercial Roaster (30kg to 70kg)

Moving past the 15kg to 30kg bracket will only be necessary when you have a huge customer base. Roasters of this size are likely to be operating on a large commercial scale.

However, at this stage, there are likely to be unforeseen expenses that come along with the purchase of a larger roaster, as Neil explains. 

“[With these bigger roasters], people often don’t have the right gas supply or ventilation in place,” he says. “It could be just too difficult to run a chimney out of the premises or a gas main in… at this size, it’s a significant consideration.

“At Genio, we offer pre-inspection through video calls or in person to make sure our larger products can fit into your space.”

Beyond ventilation and gas supply, you also have the actual size of your space to consider. As many roasters start on a small scale and gradually scale up, their premises can often only fit a few small machines. At this stage, it may be necessary to relocate.

Extra Large Commercial Roaster (70kg and up)

Beyond 70kg, extra large commercial roasters are generally used for mass roasted coffee rather than high-scoring specialty coffee. Operating a machine of this size will require a dedicated team, and it will likely be used to deliver a consistent, signature flavour profile on a wide scale rather than roasting different single origin lots, for example. 

Much like the previous size category, roasters will also have to consider the physical constraints of their space before installing a piece of equipment of this size. These roasters will often be found in large open manufacturing spaces, as they may require 50 to 60 square metres of space and often weigh over two tonnes. 

Other Points To Consider

Neil tells me that as well as floor space, ventilation, and gas supply, you also need to consider machine maintenance if you’re upgrading to a larger machine. Bigger roasters take more effort to clean and can be more complex to maintain. 

Changing the size of your roaster will also affect the profiles you have identified for roasting certain coffees. While these existing profiles can still be used as a baseline, remember that machines of different sizes will act differently during the roast. 

Be prepared to have to tweak and change. “You can’t truly copy profiles from one roaster to the other, even though we do go to extensive efforts as manufacturers to try and make that easier,” Neil says. 

However, Neil says that the time it takes to reach a certain roast profile shouldn’t really change as the size of your machine does. “Your roasting technique should not be determined by the machine,” he says. “It should be determined by the flavour profile of the coffee. But your machine must be capable of achieving these results.

“Let’s say that a bean will roast to its desired level in twelve minutes… [all good roasters] should be capable of reaching those target temperatures by that time, irrespective of the size of the machine.”

Whether you’re considering roasting coffee on the bar at your coffee shop or looking to expand the capacity of your existing roastery, there are a whole range of machines of different sizes out there to choose from.

However, as this article illustrates, choosing a roaster isn’t just as simple as figuring out how much coffee you can roast with it. Before you invest in a new roaster, ask yourself: what are your aims as a business? Do you have a sufficient market for the volume of coffee you’re planning to roast? And does that size of roaster really suit you?

Found this interesting? Don’t forget to check out How Can Roasters Build Good Relationships With Producers?

Photo credits: Genio Roasters

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Roasting coffee is all about the finer details – and this is true with the equipment you use, too. Making sure you install equipment properly at the beginning of a new venture or when making a new investment in your space can save you time and money in the long run.

One of the most important details for any coffee roasting space is ventilation. Firstly, poorly designed ventilation systems can lead to reduced airflow or blockages, which can affect the quality of your roast and become a fire hazard. 

Furthermore, if your roaster reaches temperatures that your venting system can’t properly handle, it could cause the entire system to break down, possibly endangering everyone in your roastery. To learn more about the importance of using properly installed ventilation systems when roasting coffee, I spoke to three experts.

Lee este artículo en español Cómo Elegir el Sistema de Ventilación Adecuado Para tu Tostadora

Venting Your Roaster: An Overview

To learn more about roaster ventilation, I spoke to Ryan Karatimus, President at Usonian Systems. Ryan tells me that when he started off selling roasters, he found that a lot of customers didn’t know who to turn to when it came to the more technical areas, like ventilation.

Ryan tells me that he spent a lot of time researching and understanding ventilation, which he felt was at the back of people’s minds when it came to setting up a roastery. He adds that his experience on projects involving beer brewing equipment, pizza ovens, and many different coffee roasters helped ventilation become a focus.

“It’s everywhere,” Ryan says. “You can’t go inside and look around without seeing a chimney somewhere. And setting up a good ventilation system is tons of fun, but nobody seems to know how to do it.

“We have worked with a variety of coffee roasting companies to specify and design their roaster venting system, from complicated projects through to straightforward installations.”

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Ryan explains that even though installing a quality ventilation system requires a lot of planning, the end goal is quite straightforward. He tells me that it was easy to understand venting systems by using some simple analogies. “To me, it’s just a pipe that holds a fluid,” he explains. “That’s all it is. Your fluid is the exhaust gas; you just need to route it properly.”

He adds that foresight is incredibly important. Specialist knowledge helps, and planning before you move anything into your roastery space is key. If you don’t plan ahead and your roaster ends up being in the wrong location, you might end up paying far more than you need to for a long venting run.

Ryan also highlights the importance of working with specialists who understand both coffee roasters and industrial ventilation. “I had a customer who worked with an HVAC contractor who said they knew what they were doing. However, when I came in and looked at what had been installed, I had to tell them that it just wasn’t working.  

“They had to buy a US $3,000 fan because they should have had fewer angles [in the venting run] or pipes with a wider diameter.”

Ryan and Usonian have worked with a number of roasters over the years to design bespoke, fit-for-purpose ventilation systems. However, he says that sometimes the “actual configuration” of the roaster in question can be a barrier in itself, and notes that it can “affect the appliance in weird ways”.

“You’ll see a lot of roasters vented with the cooling tray into the exhaust,” he tells me. “Even though it might have been specifically designed to do that, any equipment manufacturer, and certainly any venting manufacturer, will absolutely hate doing that.”

Make Sure You Use The Right Materials

First and foremost, good quality ventilation needs to be able to withstand the high temperatures that a roaster generates. Before you install a ventilation system, make sure that you have an understanding of how hot it needs to be.

If your system is installed by a standard, non-specialist HVAC contractor, it may not be able to endure the high temperatures that some modern roasters generate. Larry Rohskopf is the CEO of Jeremias, a specialist exhaust systems supplier. 

Larry tells me that Jeremias manufactures exhaust systems that can withstand temperatures well above what you’d expect from roasting coffee. He explains that it’s important to test every material and part you use before incorporating it into a system. As such, Jeremias supply exhaust systems that are blast tested at temperatures of well above 1,000°C to make sure they are ready for use.

Larry adds that it’s important to make sure that every part of the system can resist high temperatures, not just the main pipes and panels. Gaskets and sockets, for instance, will not have the same kind of resistance to heat as stainless steel.

“Our systems are entirely gasket-free,” Larry tells me. This means that the ventilation pipework can securely connect together without the need for less durable materials that may break down over time.

Selecting the right materials isn’t just about heat protection, however. Larry reminds me that it’s important to consider the visual appeal of your pipework, especially if you’ll be bringing potential customers into your roastery. 

“Sometimes you can actually see [the pipes], in the lobbies of coffee shops,” Larry says. “If they are made with a nice bright stainless steel, it creates a smooth-looking mirror finish that is kind of attractive.”

Design & Planning Are Key

A roastery is a unique space. Planning out how everything will fit in – including ventilation – is incredibly important. Often, you’ll be working with a room that has limitations in terms of size and shape, and will need to consider how and where your ventilation should be placed.

However, this shouldn’t be a barrier to success. By planning well ahead, you can stop ventilation from being something that needs to be considered and instead look at it as part of your roastery’s wider visual appeal. 

Firstly, make sure you account for the possibility of expansion. You might start out using a smaller roaster with a venting run that isn’t too demanding to install or maintain.

However, if you start increasing your output and upgrading to higher-capacity machines, remember that they will generally require a more substantial and complex ventilation system. Leave yourself enough space if you’re hoping to expand and roast more coffee.

It’s also important to note that you will need easy access to the ventilation to regularly clean and maintain it, much like the roaster itself. Through regular use, dust and chaff will build up in your pipes, which can cause a blockage if not appropriately addressed.

While fires generally start in the roaster itself rather than in the ventilation system, blockages will make a fire more difficult to manage in the event that it does break out.

Ryan adds that poorly designed systems don’t just pose a fire risk. If the ventilation is ineffective, it can actually back pressure, which is where the airflow comes back towards the roaster rather than leading away from it. This means that dust and chaff from roasting flow back towards the roaster, affecting the quality of your roast and making blockages more likely to occur.

Richard Sandlin is the Director of Business Development at Royal Coffee. He tells me more about one of Royal’s major projects, The Crown, an open-source coffee education centre based in Oakland, California. Richard explains that relying on outside expertise from Usonian helped them to deliver the project in the end.

“We needed an expert who was used to solving complicated problems in small spaces,” Richard tells me. “We had a number of different roasters installed in a tight space, and we needed assistance designing a one-of-a-kind stack system that was not only safe, but also true to the aesthetics of the project.”

Richard says that the planning and design was a hugely important part of a long process – not just for the venting, but for the wider space. “Designing the roasting space, building, HVAC, and eventual roaster install all took a solid 18 months.”

Ventilation is a key part of designing a space for roasting coffee. Whether you’re replacing an old roaster or setting up a new space entirely, it’s something that needs to be installed properly.

While choosing the right materials and supplier for your venting is important, make sure you plan ahead. Think the restrictions of your space and take the time to design your roastery over a period of months, not weeks.

Finally, if you’re starting a particularly complicated project, consider speaking to an outside specialist. They might be able to help you plan a space where you can safely roast great coffee for years to come.

Enjoyed this? Then read How To Clean & Maintain Your Coffee Roastery

Photo credits: Usonian Systems, Neil Soque, Ana Valencia, Bax + Towner for Royal Coffee Inc

Please note: Usonian Systems is a sponsor of Perfect Daily Grind.

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