Field of Invention

This invention relates to a chicory and dextrin based soluble coffee product and a process for preparation thereof. Specifically, but without implying any limitation thereto, the invention relates to a chicory and maltodextrin based coffee product and a process for preparation thereof.

Prior Art

Chicory (Cichorium intybus) is a bushy perennial herb with blue, lavender or occasionally white flowers, which either grows as a wild plant or is cultivated. Chicory is also known as blue sailors, succory or coffeeweed. The cultivated forms of chicory are grown for their leaves or for its roots. The young leaves of cultivated chicory are eaten raw as a salad. The roots of the chicory can also be boiled and eaten like a vegetable. Chicory has several such uses but it is best known for its use in association with coffee. Whenever the coffee has become unavailable or too costly, people have often turned to roasted chicory as a substitute for coffee. The roots of chicory are baked, ground and used as coffee substitute as well as additive. Its use as a coffee additive is very popular in India, parts of Southeast Asia and South America particularly in New Orleans.
There is no caffeine in the chicory and it produces more roasted flavour than coffee. Many coffee producers offer blends with up to 30% Chicory which cuts down the caffeine content in a cup of coffee. Chicory is also more soluble in water and therefore requires lesser quantity to prepare a cup of beverage and is therefore more economical. Chicory also offers extra health benefits than an ordinary cup of coffee. It is reported to help cleanse the blood and improve the health of liver. The roots of chicory have been also found to contain up to 20% inulin which is a polysaccharide similar to starch. The newer strains of chicory have been created which give chicory with inulin content comparable to that of sugar beet. Due to this reason, it is also used as a sweetener in food industry and also sometime added to yogurts as a probiotic.

US patent 5,958,497 reports a chicory extract powder products and extract production processes and apparatus. The process disclosed therein involves obtaining the extracts of coffee and chicory separately, mixing the two green powders thus obtained and caramelizing them together in an extruder at a temperature between 180 and 250°C.
US 5620733 reports an invention relating to milk and coffee composition for beverage preparation. The said patent discloses a process wherein milk product is heat treated to a temperature in the range of 90 to 120°C and concentrated to obtain lactic concentrate followed by addition of a liquid coffee extract. The mixture thus prepared has a pH in the range of 5.8 to 6.3 depending upon the quantity of coffee added. The mixture is homogenized preferably in two stages for instance first at 110 bar at first stage and at 50 bar at the second stage. This is followed by heating and spray drying at 95-115°C for 5 to 20 seconds.

US 6713113 discloses a foaming ingredient and powders containing it. The patent reports a powdered soluble foamer ingredient which upon addition of liquid induces the formation of or forms foam. In one of the preferred embodiment, the patent discloses a soluble creamy ingredient which is a matrix containing carbohydrate, protein and entrapped food grade gas wherein the carbohydrate preferably is maltodextrin. Another embodiment discloses a soluble beverage powder comprising a soluble coffee powder and a soluble creamy ingredient. Such beverage powders may be produced by conventional extraction and drying techniques. The process requires extruding the mixture of milk solids and maltodextrin at temperatures below 150°C, followed by injection of nitrogen at about 20°C.

Thus none of the prior art patents teach a coffee beverage product which consist of soluble coffee, chicory and dextrose/maltodextrin. Further the dry blending process used in the preparation of products disclosed in the above cited patents, produces products which have number of drawbacks.

One of the drawbacks of the maltodextrin based coffee beverage products known in the art is that it is difficult to mix the powders in a completely homogeneous way. On reconstitution, moreover, the powder mixture does not always dissolve to provide a beverage with completely homogeneous texture. There is also a loss of aromas.
Another drawback of the maltodextrin based coffee beverage products known in the art is that such products prepared by the processes of known art have poor flowablity.
Still another drawback of the maltodextrin based coffee beverage products known in the art is that the each cup of coffee prepared using such products lacks consistency, with each cup having a different profile including different colour.

Objects of the Present Invention

An object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof wherein the product provided is an instant coffee with coffee substitutes which dissolves better when reconstituted with hot or boiling water and has organoleptic properties better than products prepared by the dry-blending processes known in the art.

Another object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof wherein the proposed process is energy-efficient with about 35% less energy consuming as compared to the processes known in the art.

Another object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof which provides a soluble beverage powder which has a substantially homogeneous color.

Still another object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof wherein the soluble beverage powder provided by the invention contains a total amount of soluble coffee of at least 25% by weight.

Further object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof wherein the proposed process is different from the earlier invention in terms of procedural matrix and stages of addition of ingredients which not only helps in energy savings but also facilitates better retention of quality by obviating the need for additional heat treatments.

Still further object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof wherein product has

homogenous appearance and each cup of beverage prepared therefrom is consistent in taste, texture and aroma.

Yet further object of the present invention is to provide a chicory and dextrin based soluble coffee product and a process for preparation thereof wherein the product has superior flowability as compared to the maltrodexrin based coffee products known in the art.

Further objects and advantages of the present invention would be apparent from the ensuing description with reference to accompanying figure.

Statement of Invention

According to the present invention there is provided a chicory and dextrin based soluble coffee product comprising:

- 20 to 60% by weight of spray-dried coffee blend of Robusta and Arabica coffee taken in the ratio of 90:10;

- 20 to 60% by weight of dextrin; and

- 20 to 60% by weight of chicory

Further, according to the present invention, there is provided a process for preparation of a chicory and dextrin based soluble coffee product comprising steps of:

(a) cleaning and grading of green coffee;

(b) roasting cleaned coffee of same grade for uniform roasting, at a temperature in the range of 250 to 300°C with cycle time of 15 to 17 minutes for each batch till required color factor is attained, followed by cooling to temperature in the range of 45 to 50°C and storage for at least 6 to 8 hours;

(c) mixing of roasted Robusta and Arabica coffee in the ratio by weight of 90:10 followed by grinding to particle size of 2.5mm to 3mm;

(d) charging the grinded coffee blend to a battery of extraction units and passing pre-heated water at temperature in the range of 160 to 180°C and at a pressure in the range of 14 to 16 bars, with a cycle time of 35 to 40 minutes followed by quick cooling to 25 to 30 °C thereby obtaining a weak coffee extract containing 12 to 15% solids;

(e) wet-blending of weak coffee extract obtained by step (d) with a dextrin in the ratio of 1:0.5;

(f) concentrating the liquor as obtained by step(e) by pre-heating the liquor in the range of 80 to 90 °C subjecting it to evaporation under vacuum followed by cooling thereby obtaining concentrated liquor;

(g) wet-blending the concentrated liquor obtained by step (f) with concentrated chicory in the ratio of 1:1 and homogenizing the blend thus obtained; and

(h) spray-drying homogenized wet-blend obtained by step (g) at a temperature in the range of 200 to 220°C thereby obtaining the desired product.

Brief Description of Figures

The process of the present invention is illustrated with an accompanying figure which is intended to illustrate the process of the present invention and is not intended to be taken restrictively to imply any limitation on the nature and scope of the present invention. In the accompanying Figure:

Fig. 1:- depicts the flow chart of the process of the present invention.

Description of the Invention w.r.t. Drawings

The process for preparation of a chicory and dextrin based soluble coffee product, as per the present invention involves prior concentration of a mixture of weak coffee extract and maltodextrin (having 12 to 15% solids) to a level of 40-45% solids by evaporation under vacuum. The chicory concentrate is wet-blended with such concentrated liquor at the final stage prior to spray drying. This avoids the energy intensive phase for concentrating chicory, without any compromise on the quality of the product. This makes the process energy-efficient enabling saving in energy consumption to the extent of 35% as one ingredient (chicory) is not exposed to evaporation process. At the same time, the product obtained by the process of the present invention has superior quality as compared to the processes of known art involving dry-blending of the ingredients. The product obtained by the process of the present invention has excellent flowability as compared to the product known in the art which is very sticky in nature creating problems in handling and packing of the product. The product has a uniformly dark brown in colour which is generally preferred by the consumer as compared to the product known in the art which appears as a light brown heterogeneous mixture of white particles of maltodextrin and coffee powder. The product has significantly lower density which means that certain volume of the product of the present invention has lower weight as compared to the same volume of the product of the present invention, thereby making the product of the present invention as more economical.

Composition of the Product

According to the present invention, there is provided a chicory and dextrin based soluble coffee product, which comprises of:

(a) spray-dried coffee in the weight percent range of 20 to 60% preferably in the weight percent range of 35 to 45% wherein coffee is a blend of Robusta and Arabica coffee taken in the ratio of 80:20 preferably in the ratio of 90:10;

(b) Maltodextrin in weight percent range of 20 to 60% preferably in the weight percent range of 25 to 35%; and

(c) Chicory in the weight percent range of 20 to 60% preferably in the weight percent range of 25 to 35%.

Process of Preparation

Referring to Figure -1, the process for preparation of a chicory and dextrin based soluble coffee product of the present invention, comprises of the following steps:

(a) Green Coffee Cleaning and Grading

The green coffee is cleaned by removing all extraneous matter and it is graded for uniform roasting.

(b) Roasting and Blending

The clean green coffee as obtained by step (a) above is roasted at a temperature in the range of 250 to 300°C in drum roaster with cycle time of 15 to 17 minutes for each batch for attaining the required particular color factor. The roasted coffee is cooled to a temperature in the range 45 to 50°C and stored for minimum 6-8 hours before it is ground. A mixture of Robusta and Arabica coffee is prepared by proportionate mixing of cooled Robusta and Arabica as obtained above, in the ratio by weight of 80:20 preferably in the ratio by weight of 90:10. The mixture of Robusta and Arabica roasted coffee thus obtained is drawn in a regulated flow and ground in a triple roll grinder to a required particle size preferably in the range of 2.5 to 3mm.

(c) Preparation of Weak Coffee Extract

The extraction of the freshly grinded blend of Robusta and Arabica coffee as obtained above is carried out by quickly charging the ground coffee powder blend into a battery of extraction units. The quick charging of the coffee blend into the extraction units prevents the ground coffee blend from becoming stale . and ensures good coffee brew with rich taste and aroma. For the extraction purpose, the blended coffee powder is fed into the first stainless steel column of the battery of Extraction Units, comprising preferably of at least seven stainless steel columns. Pre-heated water at temperature in the range of 160 to 180°C and at a pressure of 14 to 16 bars is passed through this column and extract thus obtained from first column is then charged into the remaining stainless steel columns of the battery of extraction units, in a cyclic pattern, with a total cycle time of 35 to 40 minutes from first column to the last column. The extracted brew thus obtained is quickly cooled to 25 to 30°C and stored in low temperature stainless steel insulated storage tanks to protect flavour and aroma of the extract. The extracted brew has 12 to 15% solids and is referred to as weak coffee extract.

(d) Wet blending of Dextrin with Weak Coffee Extract

From the insulated storage tanks, the weak coffee extract as obtained above, is drawn and mixed with a dextrin preferably maltodextrin in a mixing tank, taking coffee extract and maltodextrin in the ratio by weight of 1:0.5 preferably in the ratio by weight of 1:0.7 to achieve final concentration of solids in the weight percent range of 12 to 15%;

(e) Concentration of Weak Extract of Coffee and Maltodextrin

The liquor as obtained above containing the weak concentration of coffee and maltodextrin is concentrated by pre-heating to a temperature in the range of 80 to 90°C and evaporating under vacuum in four stage falling film stainless steel evaporator where it is concentrated in the range of 40-45% solids. The concentrated liquor is quickly cooled to a temperature of 20 to 25°C and stored in stainless steel insulated storage tanks,
(O Wet Blending of Chicory Concentrate with Concentrate of Coffee and Maltodextrin
The concentrated coffee and maltodextrin extract as obtained above is mixed with concentrated Chicory having concentration in the range of 55 to 65%, at 1:1 ratio preferably at the ratio of 1:0.5. The mixture is homogenized in a homogenizer/high pressure pump.

(g) Spray-drying of the Wet Blend of Chicory, Coffee and Maltodextrin

The concentrated extract of Chicory, Coffee and Maltodextrin is pumped from the insulated storage tank through a high pressure pump to the top of a stainless steel spray-drying unit. The concentrate is spray-dried at temperature in the range of 200 to 220°C in the stainless steel spray drying unit where it meets the hot air at temperature in the range of 250 to 260°C which instantly dries the concentrate in a flash to flake out which cascades down the drier column along with the air stream in a fluidized pattern and becomes fully dried by the time it reaches the bottom. The powder at the bottom is collected in a stainless steel conical collection hopper fitted to the bottom of the drier which is cooled with dehumidified cold air to prevent deposition of fines inside the collection hopper.

The invention is illustrated with a following example which is intended to illustrate the working of the invention and is not intended to be taken restrictively to imply any limitation on the scope of the invention.

Example

1000 liters of weak coffee extract is mixed with 120kg of maltodextrin and is agitated. The mixture is agitated and is concentrated to about 45% solids. To this concentrated mix, 180 kg of chicory concentrate is mixed and homogenized. The mixture is spray-dried at 200°C to obtain the desired product.

Test and Evaluation

The various quality parameter of the final product obtained by the process of the present Invention were determined and these parameters were compared with the parameters of the dry-blended powder as known in the art. The results are tabulated in the Table-I below:

TABLE-I

From the test and evaluation results tabulated above, it may be noted that while pH and the moisture content of the product of the present invention are around the same as those of the corresponding product known in the art, there is substantially improvement in flowability and texture of the product of the present invention. The fluidity of the product of the present invention is 41 as compared to fluidity of 47 for the dry blended product known in the art showing thereby that the dry blended product known in the art is very sticky in nature whereas the product of the present invention has very good flowablity which property is useful in handling, storage and packing of the product. The lower parameter of Agtron colourimeter indicates that the control on colour of the product is better in the product of the present invention as compared to the dry-blended product known in the art. The product of the present invention has homogenous dark brown colour which is preferred by the consumer as compared to dry-blended product known in the art which does not have a uniform colour as maitodextrin is white and the product in the known art is prepared just by dry-biending in a mixer, of the chicory, coffee and maltodextrin. The density of the product of the present invention is also significantly low which means more product powder of the present invention per unit of weight which makes the product more economical than the dry blended product.

It is to be noted that the features of the product and process of the present invention may be employed in variant embodiments by the persons skilled in the art by making modifications, adaptation, equivalent changes in the composition or the process of the present invention. Such variant embodiments incorporating modifications, adaptations, equivalent changes are intended to be within the scope of the present invention which is further set forth under the claims that follow.

We Claim:

1. A chicory and dextrin based soluble coffee product comprising:

- 20 to 60% by weight of spray-dried coffee blend of Robusta and Arabica coffee taken in the ratio of 90:10;

- 20 to 60% by weight of dextrin; and

- 20 to 60% by weight of chicory

2. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein for said coffee blend, Robusta and Arabica coffee are taken in the ratio of 80:20.

3. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein said spray-dried coffee blend of Robusta and Arabica coffee is taken in weight percent of 35 to 45%.

4. A chicory and dextrin based soluble coffee product as claimed in ciaim-1 wherein weight percent of chicory is 25 to 35 %.

5. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein dextrin is maltodextrin.

6. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein weight percent of dextrin is 25 to 35%.

7. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein the product has fluidity around 41.

8. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein the product has colour on Agtron Colourometer in the range of 78-82.

9. A chicory and dextrin based soluble coffee product as claimed in claim-1 wherein the product has density in the range of 0.25 to 0.28 g/i.

10. A chicory and dextrin based soluble coffee product as herein substantially described.

11. A process for preparation of a chicory and dextrin based soluble coffee product comprising steps of:

(a) cleaning and grading of green coffee;

(b) roasting cleaned coffee of same grade for uniform roasting, at a temperature in the range of 250 to 300°C with cycle time of 15 to 17 minutes for each batch till required color factor is attained, followed by cooling to temperature in the range of 45 to 50°C and storage for at least 6 to 8 hours;

(c) mixing of roasted Robusta and Arabica coffee in the ratio by weight of 90:10 followed by grinding to particle size of 2.5mm to 3mm;

(d) charging the grinded coffee blend to a battery of extraction units and passing pre-heated water at temperature in the range of 160 to 180°C and at a pressure in the range of 14 to 16 bars, with a cycle time of 35 to 40 minutes followed by quick cooling to 25 to 30 °C thereby obtaining a weak coffee extract containing 12 to 15% solids;

(e) wet-blending of weak coffee extract obtained by step (d) with a dextrin in the ratio of 1:0.5;

(f) concentrating the liquor as obtained by step(e) by pre-heating the liquor in the range of 80 to 90 °C subjecting it to evaporation under vacuum followed by cooling thereby obtaining concentrated liquor;

(g) wet-blending the concentrated liquor obtained by step (f) with concentrated chicory in the ratio of 1:1 and homogenizing the blend thus obtained; and

(h) spray-drying homogenized wet-blend obtained by step (g) at a temperature in the range of 200 to 220°C thereby obtaining the desired product.

12. A process for preparation of a chicory and dextrin based soluble coffee product as claimed in claim-11 wherein roasted Robusta and Arabica coffee are mixed in the ratio by weight of 80:10.

13. A process for preparation of a chicory and dextrin based soluble coffee product as claimed in claim-11 wherein said weak coffee extract and dextrin are wet-blended in the ratio of 1:0.7

14. A process for preparation of a chicory and dextrin based soluble coffee product as claimed in claim-11 wherein said concentrated liquor of coffee extract and dextrin as obtained by step (f) is wet-blended with concentrated chicory in the ratio of 1:0.5.

15. A process for preparation of a chicory and dextrin based soluble coffee product as claimed in claim-11 wherein dextrin is maltodextrin.

16. A process for preparation of a chicory and dextrin based soluble coffee product as claimed in claim-11 wherein said concentrated liquor obtained by step (f) of claim-1 has 40 to 45% solids.

17. A process for preparation of a chicory and dextrin based soluble coffee product as claimed in claim-11 wherein chicory concentrate taken has concentration in the range of 55 To 65%.

18. A process for preparation of a chicory and dextrin based soluble coffee product as herein described and illustrated with accompanying figure.