Instant Coffee Production Line and Factory Setup

An instant coffee production line is an integrated industrial system designed to clean and roast green coffee, extract soluble solids, concentrate the extract under vacuum, dry it by spray drying or freeze drying, agglomerate the powder into granules and package the finished instant coffee under controlled hygienic conditions. The line produces soluble coffee with low residual moisture and good solubility.

From an industrial perspective, instant coffee manufacturing is important because it combines precise roasting, multi-stage extraction, vacuum concentration, spray or freeze drying and agglomeration to achieve consistent solubility, aroma retention and shelf life. The process relies on a defined sequence of unit operations that must be correctly engineered and integrated.

Primary raw materials typically include green coffee beans and process water. Core machinery consists of green-coffee cleaners, roasters, extraction units, vacuum evaporators, spray dryers (or freeze dryers), agglomerators and CIP systems.

The Industrial Department supports investors establishing a new instant coffee factory as well as existing plant owners requiring repair, overhaul, capacity expansion or automation of current instant-coffee lines. Projects can start from an empty site or from an operating facility that needs technical upgrading.

Whether the goal is a green-field turnkey instant coffee plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The instant coffee production line is engineered as an integrated process system covering green-coffee pretreatment, roasting, extraction, solid-liquid separation, vacuum concentration, spray or freeze drying, agglomeration and packaging, together with CIP. Design capacity is determined during the engineering phase and can typically range from 10–800 kg/h depending on final product mix and market requirements.

Product types include spray-dried or freeze-dried instant coffee, agglomerated granules and various retail or bulk packaging formats. Final moisture is typically kept below 3 % and bulk density in the range 0.18–0.35 kg/L. The overall process flow follows a defined sequence: pretreatment of green coffee, roasting, extraction, separation, concentration, drying, agglomeration and packaging.

Main machinery groups include green-coffee cleaners, roasters, extraction units, vacuum evaporators, spray dryers (or freeze dryers), agglomerators, packaging machines and CIP systems. Supporting infrastructure covers electrical power, gas, process water, steam and compressed air.

Manpower requirements depend on the degree of automation. Quality control covers green-bean quality, roast profile, extract concentration, residual moisture, solubility and packaging integrity. Finished instant coffee is stored under dry, low-humidity conditions before distribution.

Technical Specifications

The following technical data represent typical ranges for an industrial instant coffee production line. Final values are defined during basic and detailed engineering and may vary according to selected technology, level of automation, product portfolio and factory layout. For precise project-specific figures, contact the Industrial Department.

Specification	Description
Product	Instant coffee (spray-dried or freeze-dried, agglomerated granules)
Production Capacity	10–800 kg/h (depending on project capacity and selected equipment sizing)
Required Area	500–1000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 100–200 kW (depending on equipment selection and automation level)
Gas	100–300 m³/h
Water Consumption	10–30 m³/day
Manpower	8–15 persons per shift (depending on automation level)
Main Machines	Green-coffee cleaner, roaster, extraction unit, vacuum evaporator, spray dryer (or freeze dryer), agglomerator, CIP system
Final Moisture	Typically less than 3 %
Bulk Density	Typically 0.18–0.35 kg/L

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial instant coffee production line can manufacture a variety of finished products depending on the selected drying and agglomeration configuration. Typical product families include:

Spray-dried instant coffee
Freeze-dried instant coffee
Agglomerated granules for improved solubility
Retail and bulk packaging formats

Variant development (roast level, solubility, granule size, packaging) is defined during product development and process engineering according to target markets.

Raw Materials for Instant Coffee Factory

Raw material selection and quality control are critical for extract yield, aroma and solubility. The main materials used are described below.

Main Raw Materials

Green coffee beans – Quality of incoming beans directly influences extract yield and final cup quality.
Process water – Used for extraction; must meet process-water standards.

Secondary / Optional Materials

Packaging materials (moisture-barrier bags or jars)

Storage and handling conditions (cool, dry, pest-controlled) must be maintained to preserve green-bean quality before processing.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by instant coffee factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Instant Coffee
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial instant coffee projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

The industrial instant coffee process follows a defined sequence of unit operations.

Green Coffee Pretreatment – Impurities are removed and beans are prepared for roasting.
Roasting – Green beans are roasted at 200–250 °C to develop flavor and aroma.
Extraction – Soluble solids are extracted from roasted beans with water under controlled temperature and pressure.
Separation – Extract is separated from spent grounds.
Concentration – Extract is concentrated under vacuum in an evaporator.
Drying – Concentrated extract is dried by spray drying or freeze drying to a fine powder with residual moisture typically below 3 %.
Agglomeration – Powder is agglomerated into granules to improve solubility and flow.
Packaging and CIP – Finished instant coffee is packaged in moisture-barrier containers; the line is cleaned by CIP.

Machinery & Equipment

Each main machine performs a specific function. Support is available for design, manufacturing or procurement, customization, installation, commissioning, repair, overhaul, refurbishment, automation and spare-parts supply according to the agreed project scope.

Green-Coffee Cleaner – Removes impurities. Position: first stage. Importance: protects downstream equipment. Maintenance: screens and fans. Sahi Rasa support covers design and spare parts.
Coffee Roaster – Roasts beans under controlled conditions. Position: after cleaning. Quality impact: roast profile defines extract flavor. Maintenance: burners, drums and sensors. Sahi Rasa provides specialized roaster support.
Extraction Unit – Extracts soluble solids with water. Core machine for yield. Position: after roasting. Quality impact: temperature, pressure and time control extract concentration and quality. Maintenance: vessels, pumps and seals.
Vacuum Evaporator – Concentrates the extract under vacuum. Position: after separation. Quality impact: concentration level affects dryer load and final product density. Maintenance: heat exchangers, vacuum system and seals. Sahi Rasa provides specialized evaporator support and overhaul.
Spray Dryer (or Freeze Dryer) – Converts concentrated extract into powder. Core machine for residual moisture and solubility. Position: after concentration. Quality impact: inlet/outlet temperatures and atomization control particle size and moisture. Maintenance: atomizers, chambers, cyclones and air heaters. Sahi Rasa provides specialized dryer support and overhaul.
Agglomerator – Converts fine powder into granules. Position: after drying. Quality impact: improves solubility and flowability. Maintenance: nozzles, chambers and air systems.
CIP System – Automated cleaning of process equipment. Position: integrated throughout the line. Importance: hygiene and product safety. Maintenance: pumps, valves and tanks.

Factory Layout & Building Requirements

Typical functional areas include green-bean receiving and storage, roasting and extraction hall, concentration and drying area, agglomeration and packaging, finished-goods warehouse, quality-control laboratory, utility rooms (steam, gas, compressed air), CIP room, maintenance workshop, staff facilities and loading docks. Layout must respect hygienic zoning, heat and moisture control and process flow. Exact area allocation is determined during the engineering phase according to capacity and product range.

Utilities

Electricity: 380 V three-phase, typically 100–200 kW
Gas: 100–300 m³/h
Water: 10–30 m³/day
Steam and compressed air as required
HVAC and drainage according to hygiene and local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC (Engineering, Procurement, Construction) or PMC (Project Management Consultancy) approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing instant coffee factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for extractors, evaporators, spray dryers, agglomerators and CIP systems.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn atomizers and heat exchangers, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (extractor, dryer, agglomerator), improving material handling or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and vacuum monitoring, automatic dosing, HMI, data logging and optional SCADA integration, together with CIP automation.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for instant coffee projects.

Packaging

Moisture-barrier packaging, secondary packaging, labeling, coding, cartoning and palletizing are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, industrial design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for instant coffee projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new instant coffee factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up an instant coffee production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Instant Coffee

FAQ

What is the typical cost of setting up an instant coffee factory?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Green-coffee cleaner, roaster, extraction unit, vacuum evaporator, spray dryer (or freeze dryer), agglomerator and CIP system.
What production capacity can be designed?
Typical capacity ranges from 10 to 800 kg/h, determined during the engineering phase.
How much space is needed?
Typical process area ranges from approximately 500 to 1000 m², subject to final layout.
What are the main raw materials?
Green coffee beans, process water and packaging materials.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.