Main types of equipment in coffee processing include Dryers

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The Codex General Principles of Food Hygiene
Establishment design and facilities

• Module 3.2

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Objectives

• To make trainees aware of the importance of good
  hygienic design and construction of food
  establishments
• To relate the general code to the handling and
  processing of coffee
• To create awareness of the roles of different
  stakeholders in ensuring good practices

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Content

• Scope and objectives of Section IV of the Codex
  General Principles of Food Hygiene
• Discussion of food hygiene principles relevant to
  Establishment design and facilities and their
  application to coffee handling and processing
• Discussion of the roles of producers and
  government in ensuring good practices

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Establishment design and facilities

• Objective of Section IV
• Depending on the nature of the operations, and
  the risks associated with them, food
  establishments should be designed and constructed
  and equipped to ensure that
• Contamination is minimised
• Appropriate maintenance cleaning and disinfection
  is permitted

• Codex definition of establishment
• ...Any building or area in which food is handled
  and the surroundings under the control of the
  same management.

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Establishment design and facilities

• Section IV of Codex GPFH covers
• Location of establishments
• Premises and rooms design, layout and internal
  structures
• Design of equipment and its placement in the
  establishment
• Supporting facilities and services

Food hygiene considerations are important at the
very first stages of planning a food establishment
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Location of establishments

• Establishments should not be located near
• Polluted areas that pose a serious threat of
  contaminating food
• Areas prone to pest infestation
• Areas prone to flooding, high humidity, etc.
• Areas from which waste cannot be easily removed

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Design and layout of establishments

• Internal design and layout of establishment
  should
• Permit good hygiene practices
• Minimise possibility of cross contamination

• There should be separate channels for
• Raw material (fresh cherries)
• Intermediate product (parchment, dry cherries)
• Waste (pulp, husk)
• Final product (green beans)

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Layout of facility

• To optimize proper functioning of each element of
  procedure
• Pulpers should be located near a clean water
  source
• Fermentation vats should be located near to
  pulpers
• Waste outlet should be directed away from
  production and processing areas
• Drying yards and other processing areas should be
  away from contamination vectors

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Design and construction of drying areas

• Coffee drying yards should have
• Adequate capacity
• Smooth drying surfaces
• Adequate provisions for drainage
• Full exposure to sunlight

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Design and construction offermentation vats

• Fermentation vats should
• Be located in the pulping house
• Be adequate in number and capacity
• Have smooth surfaces
• Have a maximum depth of 1m
• Slope gently towards the outlet

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Internal structures and fittings

• Internal structures should be
• Made of durable materials
• Easy to clean and maintain

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Internal structures and fittings

• General considerations
• Walls and partitions should be easily cleaned
• Floors should be constructed to allow adequate
  cleaning and drainage
• Ceilings and overhead fixtures should be
  constructed to minimise build up of dirt and
  condensate
• Working surfaces in direct contact with food
  should be durable and easy to clean

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Facilities - air quality and ventilation

• Adequate ventilation is required to
• Minimise build-up of dust and husk particles from
  handling operations
• Control temperature and prevent condensation
• Dissipate odours that might taint the coffee

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Facilities - lighting
Adequate natural or artificial lighting should be
provided to enable operations to be carried out
satisfactorily
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Facilities - storage

• Adequate storage facilities should be provided
  for coffee to permit
• Adequate maintenance and cleaning
• Avoid pest access and harbourage

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Facilities - storage

• Adequate storage facilities should be provided
  for coffee to
• Enable food to be protected from contamination
  during storage

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Facilities

• Containers for storage of dangerous materials
  (fuel, chemicals for cleaning, disinfestation,
  etc.) should be clearly marked and safely stored
• Water supply - water of acceptable quality
  standard should be available for processing
• Systems carrying unsuitable water should be
  separate
• Electricity supply operators should ensure
  alternative sources of electricity in case of
  cuts to the central power supply

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Facilities

• Drainage and waste disposal
• Cleaning facilities - should allow for adequate
  cleaning of equipment and facilities
• Personal hygiene facilities - adequate toilet,
  handwashing and changing facilities should be
  provided for staff

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Design of equipment
Equipment should be designed and constructed to
ensure that they can be adequately cleaned and
maintained
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Design of equipment
Where necessary, equipment should be movable or
capable of being disassembled to allow for
maintenance, cleaning, monitoring, etc.
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Design of equipment

• Equipment should be designed such that their
  operation is compatible with conditions necessary
  to ensure food safety and suitability. Main types
  of equipment in coffee processing include
• Dryers
• Pulpers
• Hullers
• Sorting equipment
• Moisture monitoring equipment

Several variations of basic coffee processing
technology exist and different equipment may be
used
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Design features of simplesun-drying equipment

• Coffee is spread on a support (wire tray, woven
  mat, etc.) raised off the ground. Air can
  circulate freely above and below the support
• Trays might be movable or fixed
• When raining, trays are moved under a shelter or
  covered with plastic or any other material

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Design of simple solar dryers
Parabolic solar dryers - the shape of the
transparent roof is more or less cylindrical so
as to concentrate heat in the drying zone and
protect from rain.
Heat cumulates between the coffee and the plastic
and the air starts to circulate. This dryer is
mounted on a pivot so it can be turned towards
the sun.
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Design of simple solar dryers

• Various solar dryer designs can give faster
  drying times by
• Improving airflow and increasing temperature of
  drying air
• Participatory approaches are necessary if
  potential advantages of solar technology are to
  be matched with farmers needs
• Capacity, capital cost, running costs, space
  requirement, ease of management, etc.
• For additional information see Section 5 of
  Introduction to coffee drying .pdf

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Design of equipment mechanical dryers

• Mechanical batch dryers are used in coffee drying
  - primarily for parchment
• Horizontal dryers
• Vertical dryers
• Fixed-bed type dryers

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Design features of pulpers

• Traditional designs are drum and disc pulpers
• Main performance criteria include
• Capacity separation efficiency physical damage
  to product durability ease of maintenance and
  cleaning

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Design features of pulpers

• Important innovations are
• Low water-use pulpers
• Pulping systems that accept mixtures of green and
  ripe cherry and separate the greens without
  crushing

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Design of hullers

• Considerations in the selection of a huller
  include
• Capacity
• Energy requirement
• Efficiency of husk removal
• Extent of physical damage to beans
• Separation of loose husk
• Durability
• Ease of maintenance

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Equipment for control and monitoring

• Methods for the determination of water in coffee
• can be categorised as follows
• Direct
• Removal of water and determination of weight loss
• Indirect
• Some variable that is dependant on moisture is
  measured
• Empirical subjective
• This includes methods such as biting, shaking and
  cutting
• NB - These empirical methods of moisture
  determination in coffee have been shown to be
  unreliable

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Equipment for control and monitoring

• Factors to be considered include
• Cost
• Transportability
• Robustness
• Stability
• Repeatability
• Sensitivity
• Accuracy
• Rapidity
• The choice of method / equipment depends on
• How the equipment is to be used
• Who is to use it

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Equipment for monitoringmoisture in the field

• Restricting water availability is the main method
  for control of mould growth and development
  throughout the coffee chain
• The global coffee project has investigated
  methods of moisture determination so as to
  identify methods suitable for use in the field

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Location of equipment

• Equipment should be located
• To permit adequate maintenance and cleaning
• In accordance with requirements for proper
  functioning
• To facilitate good hygiene practices, including
  monitoring

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Assessment of establishment

• A plant assessment can help processors determine
  if facility design is appropriate
• A checklist containing all vital areas and items
  to be considered should be prepared
• During the inspection notes should be made in
  relation to all points contained in checklist
• Evaluation of the design and construction of the
  establishment and facilities should be based on
  thorough knowledge of operations and potential
  hazards
• Corrective action taken according to evaluation

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Assessment of establishment
Government
Local coffee industry

• Establish national standards, codes of practice,
  etc.
• Support industry efforts to meet required
  regulations (information dissemination, new
  equipment design etc.)
• Provide oversight to ensure industry compliance

• Collaborate with government in developing sound
  and practicable guidelines and standards
• Entrepreneurs must ensure that the design of
  their establishment is consistent with principles
  of food hygiene
• Entrepreneurs must establish adequate hygiene
  and GMP programmes to ensure that equipment
  functions properly and that they do not lead to
  hazards in the coffee

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Summary

• Inappropriate site selection for coffee
  processing facilities can lead to quality and
  safety problems in the product
• Plant layout should minimize the opportunity for
  cross contamination
• Facility design and construction can affect the
  quality and safety of coffee
• Equipment must be designed and located so as to
  facilitate its correct functioning, sanitation
  and maintenance
• Government and industry must work together to
  improve hygiene conditions of coffee processing
  establishments