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INTRODUCTION

Coffee is a beanlike seed of tropical evergreen shrub of the genus Coffea, in the

Madder family (Rubiaceae), which has opposite leaves, cream-colored flowers, and berry-

like fruit. It is the second important product in the international commerce based on the

volume traded and it is estimated to be the first based on value; are used in flavors and

extracts (Pizon, 2003).

There are 25 major species of coffee but there are only two that are likely to be

familiar, Coffea arabica and the Coffea anaphora producing robusta beans (Encyclopedia

Americana, 1998).

In dry techniques, the coffee fruits are set in the sun on enormous yards for about

fourteen days or more and raked a few times each day to encourage notwithstanding

drying (Pizon, 2003).

A good quality cup of coffee is reliant on many factors, such as the quality of green

beans, the roasting conditions, the time since the beans are roasted, and the type of water

used for brewing. More than 800 volatile compounds have been identified in roasted

coffee, whereof around 30 compounds are responsible for the main impression of coffee

aroma (Baggenstoss et al. 2008).

The value of coffee is estimated to reach two billion dollars a year or 1% of the

total world trade. Among major agricultural products of the world, coffee is unusual

because its cultivation, harvesting and much of processing remain largely untouched by

mechanization (Compton’s Encyclopedia, 1986).

Today, coffee is known worldwide and has ranked second to oil in terms of global

demand. About 25 million people worldwide, mostly small farmers, depend on coffee

farming for livelihood. One hundred forty-five million bags (@60 kg/bag) of coffee were

produced by exporting countries valued at the US $ 21 billion. Around 34% of the total
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production came from Brazil, followed by Vietnam and Indonesia, with 18% and 8%

contributions, respectively. The Philippine coffee production accounted for less than one

percent (1%) livelihood (International Coffee Organization (ICO), 2013).

The country has 119,999 hectares of land devoted to coffee with an estimated 83.5

million fruit-bearing trees. The bulk of production is in Mindanao with 64% of the total land

area and 69% of the total number of fruit-bearing trees, respectively. SOCCKSARGEN

has the largest coffee farm area with 25,223 hectares, followed by the Davao Region with

25,166 hectares, ARMM with 13,746 hectares, CALABARZON with 13,563 hectares, and

Northern Mindanao with 11,837 hectares (Bureau of Agricultural Statistics, 2012).

Despite its potential, coffee does not contribute much to the gross value of

agriculture in the country. From 2011 to 2013, the gross value of coffee output was valued

at PHP 5.8 million annually, on average. A decreasing rate on the gross value of coffee

was recorded from 2011-2013. Moreover, from the 1.2% contribution of the agriculture

and forestry sector to the country's Gross Domestic Product (GDP) in 2013, coffee

contributed a mere 0.5% to total gross value (National Statistical Coordination Board

(NSCB), 2013).

Coffee processing today had been enhanced by technologies through mechanical

roasters in roasting to reduce operational cost and labor. The coffee roaster minimizes the

damage to beans and is proven to be a better method with faster and greater outputs.

Roasting brings out the aroma and flavor that is locked inside the green coffee

beans. It causes chemical changes to take place as the beans are rapidly brought to very

high temperatures (NCA National Coffee Association).

Using the coffee roaster, this research aims to yield a satisfactory roasting quality

of coffee beans based on its appearance after the process. Thus, this study dug into

fabricating a mechanized coffee bean roaster to make it more efficient and effective for

roasting coffee beans. This machine would help the small-scale coffee growers to reduce
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the time and effort of roasting their product or selling their unroasted coffee beans directly

at a lower price.

Moreover, this study also serves as a reference for further enhancement of the

process of roasting coffee beans that would help small-scale farmers to construct a

mechanical roaster, which is locally fabricated; not only for coffee but also for other bean

crops to increase their income and quality.

Objectives of the Study

The main objective of this study is to design, construct and evaluate the

performance of a coffee bean roaster.

Specifically, this study is aimed to:

1. Evaluate the performance and quality of the roaster, in terms of

a. Roasting Efficiency

b. Roasted Beans Quality in terms of:

1) Color/appearance;

2) Aroma; and

3) Taste

2. Perform an economic estimate using Benefit-Cost Ratio

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REVIEW OF RELATED LITERATURE

Coffee Description

The coffee plant is a shrub that belongs to the family Rubiaceae, genus Coffea.

The plant consists of one or more trunks from which stem the primary branches. In the

wild, the plant grows to a height of 8-10 meters whereas, in plantations, the plants are kept

to a height of 2-2.5 meters. The leaves grow in opposite pairs, are 10-15 centimeters long

and oval or lanceolate in shape. They are deep rich green, glossy and fleshy on their

surface and overall are not unlike laurel leaves, with the characteristic wavy edge. The

flowers are white and always grow in clusters of two or three together, reaching almost 2

centimeters in size. The fruit which develops from the ovary of the fertilized flower is called

drupe or berry; it is about 15 millimeters in diameter and turns bright red when fully ripe.

The outer covering of the drupe is a thick pulpy skin, which encloses a layer of jelly-like

pulp, about 2 millimeters thick. Inside this are the seeds or beans.

Figure 1. Matured coffee beans.

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The average coffee plant is about 10 millimeters in length, weigh about 0.15 grams

each and are green in color, tinged with shades varying from grey to blue or from red to

brown. These beans are the only part of the fruits of the coffee plant that are used: the

rest is discarded during the processing (J. De Wit, 2005).

Harvesting

In the Philippines, coffee is harvested manually. The ideal method is by selectively

removing the yellow and red ripe berries from the cluster leaving the green or immature

berries for the future harvest. This method of harvesting ensures better quality Green

Coffee Beans (GCB). On harvesting, the coffee beans must be quickly processed to

control the unfathomable reaction that affects the flavor of the coffee. Coffee trees yield

an average of 2 to 4 kilos of cherries and a good picker can harvest 45 to 90 kilos of coffee

cherry per day; this will produce nine to 18 kilos of coffee beans. Coffee is harvested in

one of two ways:

Strip Picked – all the cherries are stripped off of the branch at one time, either by machine

or by hand.

Selectively Picked – only the ripe cherries are harvested and they are picked by hand.

Processing

Coffee cherries must be processed immediately after harvest to prevent spoilage.

Producers employ two processing methods: sun-drying and washing (Illy, 2002). Effective

sun-drying is accomplished by spreading the cherries out on a patio and stirring the

desiccating fruit frequently to evenly heat and aerate it. The dried cherries are run through

a machine that crushes the hulls and then removes both the hulls and the surrounding

parchment membrane layer, thus freeing the beans for sorting and bagging. In the

alternative approach, the fruit is mechanically pulped, washed, and finally dried and
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liberated from the parchment covering. The goal of either route is the same: the 65 percent

water content of the coffee cherry is reduced to the 10 to 12 percent moisture level of a

prime raw, or green, coffee bean.

Roasting of Coffee Beans

Green coffee beans provide neither the characteristic aroma nor flavor of brewed

coffee until they are roasted. Moreover, the roasting process increases the value of coffee

beans, by 100-300% of the raw material (Yeretzian et al. 2002). Roasting of coffee beans

typically takes place at 200-240°C for different times depending on the desired

characteristics of the final product. Events that take place during roasting are complex,

resulting in the destruction of some compounds initially present in green beans and the

formation of volatile compounds that are important contributors to the characteristic of

coffee's aroma. The chemical compositions of green, roasted, and brewed coffee are

shown in Figure 2 (Barter 2004).

Figure 2. Chemical composition of green, roasted, and brewed coffee (Barter 2004).
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Briefly, as temperature increments to about 100⁰C, green espresso beans

experience dampness misfortune from 8-12% in green espresso beans to about 5% in the

cooked espresso beans (Illy and Viani 1998). The smell of the beans changes from herb-

like green bean fragrance to bread-like, the shading abandons green to yellowish, and the

structure changes from quality and durability to all the more brittle and fragile. At the point

when the inward temperature of beans achieves 100⁰C, the shading obscured somewhat

for around 20-60 seconds because of the vaporization of water. At 160-170⁰C, the beans

become lighter in shading for around 60-100 seconds. As roasting cellulose (non Hyd)

18% cellulose (Hyd) 13% starches and pectins 13% soluble carbohydrates 9% water 12%

non volatile acids 7% caffeine 1% protein 12% ash 3% oil 11% trigonelline 1% Green

coffee beans caffeine 1% water 2% starches and pectins 14% CO2 2% cellulose (Hyd)

14% cellulose (non Hyd) 17% trigonelline 1% oil 13% ash 4% protein 13% non volatile

acids 7% soluble carbohydrates 10% Roasted coffee beans oil 1% soluble carbohydrates

37% non volatile acids 31% caffeine 6% protein 5% ash 16% trigonelline 4% Brewed

solubles 10 continues at this temperature, Maillard and pyrolytic reactions start to take

place, resulting in gradually darkening of the beans (Hernandez et al. 2007). The buildup

of water pressure, along with a large number of gases generated causes the cellulose cell

wall to crack, giving rise to the so-called "first crack". As heating continues at the roasting

temperature (160-170⁰C), the coffee becomes darker and more rapid popping of coffee

bean occurs ("second crack") as the carbon dioxide (CO2) buildup exceeds the strength

of the cellulosic walls of the bean. Finally, after roasting, the fresh-roasted coffee beans

are quickly cooled to stop roasting (Yeretzian et al. 2002).

The final quality of roasted coffee is influenced by the design of the roasters and

time-temperature profiles used. Although heat transfers during roasting can involve

conduction, convection, and radiation, convection by far is the most important mode of

heat transfer that determines the rate and uniformity of roasting (Baggenstoss et al. 2008).
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Coffees roasted in the fluidized-bed roaster that is almost exclusively based on convective

heating can result in low density and high yield coffee (Eggers & Pietsch 2001). On the

other hand, coffees roasted in drum roaster that involves mainly conductive heat transfer

have less soluble solids, more degradation of chlorogenic acids, more burnt flavor, and

higher loss of volatiles than the fluidized bed roasters (Nagaraju et al. 1997).

Contingent upon the degree of warmth treatment, coffee can be to a great extent

sorted as light, medium or dim dishes. The light dish procedure will, in general, give non-

uniform bean shading with harsh, green, and immature flavor, while the medium meal

procedure creates a decent taste and fragrance with the citrus season. On the other hand,

the dim meal procedure produces espresso of low causticity tactile profiles (Lyman et al.

2003). Physical characteristics such as temperature, color, and weight-loss are often used

as indicators of roast degree. However, these parameters only allow the assessment of

the flavor profile for coffee roasted under narrow process conditions (Sivetz 1991; Illy &

Viani 1995). Other analytical methods for quantifying the degree of roast include the ratio

of free amino acids (Nehring & Maier 1992), alkyl pyrazines (Hashim & Chaveron 1995),

and chlorogenic acids content (Illy & Viani 1995). Fobe and others (Fobe et al. 1968) 12

studied changes in the chemical composition of Arabica coffee roasted at 230°C at

different process times. They reported that as the roasting time increased, the following

changes occurred: (1) sugar contents first increased, and then decreased; (2) minimal

change in caffeine content; (3) proteins decreased continuously; (4) free fatty acids

increased; and (5) unsaponifiable compounds decreased (Fobe et al. 1968).

Coffee-roasting is a process of pyrolysis which, by increasing the temperature of

the coffee from room temperature to 200-230ºC, brings about marked physical and

chemical changes in the beans that improve the quality of coffee and make it easier to

prepare. These take place only at the highest temperature, so the higher the temperature

the darker the coffee (J. De Wit, 2005).

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For coffee farmers, roasting is also an important process that when optimally

utilized can provide them with better profit. Often, coffee farmers in the Philippines, like

those around the world, only sell their beans in raw form (green beans). If they can roast

their own coffee, either individually or through the cooperative, they can sell their

processed coffee at a better price rather than selling just the raw coffee beans. There is,

therefore, a need for locally manufactured coffee roaster specifically for small scale

roasting purposes to boost the small scale coffee growers in the country (Dela Cruz, 2007).

Depending on the temperatures and procedures applied, the roasting process can

last from 90 seconds to as long as 40 minutes. Twelve minutes, however, is the traditional

duration. The higher the final temperature of the roasting, the less desirable the aroma will

be and the stronger the bitterness. Conversely, low roasting temperatures fail to develop

fully the welcome aromas, and acidity tends to come to the fore (Ernesto Illy, 2002).

The coffee-roasting machine is a specialized oven that transfers heat to coffee

beans in a stream of hot gas while continually mixing the beans to ensure they roast

evenly. Several types of roasters are in use today in the specialty coffee industry: classic

drum roasters, indirectly heated drum roasters, fluid bed roasters, recirculation roasters,

and several others. Recirculation roasters return a portion of the exhaust air to the burner

chamber to assist in heat generation for roasting. The term single-pass refers to machines

that do not recirculate exhaust air. Each roaster design has distinct advantages and

disadvantages, though no new design has eclipsed the popularity of the classic drum

roaster, the design of which has not changed much in the past century (Rao, 2014).

Roaster Drum Speed

To prevent the centrifugal force from counterbalancing gravity and causing beans

to stay at the drum wall without falling, horizontal-drum roasters have to rotate with an

RPM smaller than (30/π) (g/r), where g is the gravitational acceleration and r is the drum
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radius. The larger the radius of a horizontal-drum roaster is, the slower the drum must

turn. Therefore, larger, horizontal-drum roasters provide poorer mixing than smaller

roasters of the same type. As RPM increases, beans fall off flights at higher angles of

rotation. The flights impart their velocity to beans falling off them. Thus beans fall in curved

paths that rise slightly before descending. Bean exposure to flowing hot gas is maximized

at an optimal RPM 10% to 25% less than (30/π) (g/r) (http://coffeenavigated.net/roasting-

coffee/#drum) (Illy, A. and Viani, R. (1995)).

Physicochemical Characteristics of Roasted Coffee

Roasting is an important processing step that develops the unique chemical,

physical, and sensorial characteristics of roasted coffees. The physicochemical properties

developed depend on the coffee variety, origin, and roasting conditions. In general, the

color of roasted coffee beans ranges from light–dark brown to black, depending on the

degree of roast. Roasted beans are brittle due to reduced moisture content, expanded

volume, and increased porosity after roasting. Macropores, mesopores, and micropores

are produced after roasting, which is important in determining physical and chemical

changes of roasted coffee during storage. Due to the complex Maillard, pyrolysis, and

other reactions involved during roasting, the chemical composition of roasted coffee

altered considerably compared with the unroasted green beans. The combined physical

and chemical properties affect the brewing process and thus the flavor, body, color, as

well as the concentration of compounds in the coffee beverage that have an impact on

health (Wang & Lim, 2015).

Coffee Flavor

Chemical compounds present in roasted coffee can be roughly grouped into

volatile and non-volatile, some of the former being responsible for the aroma and the latter
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for the basic taste sensations of sourness, bitterness, and astringency (Buffo & Cardelli-

Freire 2004). Russwurm reported that carbohydrates, proteins, peptides, and free amino

acids, polyamines and tryptamines, lipids, phenolic acids, trigonelline, and various non-

volatile acids in the green coffee beans were involved in the flavor formation during

roasting (Russwurm 1970).

Over time the coffee industry has come to use standardized terms to help

distinguish between flavor characteristics. The principle terms used to define a coffee’s

distinctive flavor within the green bean itself are floral, grassy, herby, peanutty, sour, and

sweet according to (Dolf DeRovira, 2006).

Figure 3: Coffee Flavor Wheel.

(Adapted from that of the Specialty Coffee Association of America, 2016)

Moisture

Moisture in coffee beans matters. Its content indicates the maturity of the beans,

the amount of drying the beans require, and the weight loss of the green beans during

storage and roasting, all of which decide the quality of the finished product. Moisture
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control can be used as a prerequisite step to optimize roasting conditions from a

manufacturing standpoint (Chiou et al., 1989).

A typical, unprocessed, ripe coffee bean should contain roughly 45–55% moisture

after picking. Processing and drying will then take its moisture content down to 10–12%

(Tom Pashley, 2017).

Temperature

The roast temperature decides both flavor arrangement and auxiliary item

properties. 3 Different temperature profiles influence a lack of hydration and the

concoction response conditions in the bean which control gas arrangement, sautéing and

season improvement. All in all, the utilization of the cooking temperature of more

noteworthy than 200°C is required to bring about alluring compound, physical, basic, and

sensorial changes in the coffee beans (Clarke and Macrae 1988; Schenker 2000;

Schenker et al. 2002; Baggenstoss et al. 2008). Shading change and weight reduction are

much of the time utilized as a proportion of the level of roast, and both are legitimately

identified with the last simmering temperature (Sivetz 1991; Illy and Viani 1995). Different

strategies, for example, the proportions of free amino acids (Nehring and Maier 1992),

and chlorogenic acids content (Illy and Viani 1995) have additionally been utilized. The

effects of time-temperature profile on coffee aroma properties. In general, low-

temperature-long time roast processes result in sour, grassy, woody, and underdeveloped

flavor properties. In comparison, high-temperature-short-time produced higher quality

coffee in terms of producing more aroma volatiles and higher brew yield (Schenker et al.

2002; Lyman et al. 2003).

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Coffee Production Trends

Global Production

The monthly average of the ICO composite indicator rose by 7.1% to 99.97 US

cents/lb in June 2019, which is the first increase in the monthly average since January

2019. In May 2019, world coffee exports rose by 19.4% to 11.6 million bags compared to

May 2018 while exports in the first eight months of coffee year 2018/19 rose by 7.5% to

86.57 million bags. Demand for coffee appears to be strong as imports by ICO importing

Members and the United States, which account for around 75% of global imports,

increased by 4.9% to 66.56 million bags in the first six months of coffee year 2018/19.

Global coffee consumption is estimated to grow by 2% to 164.64 million bags in coffee

year 2018/19. Despite the ongoing demand growth, a global production surplus of 3.11

million bags is expected in coffee (International Coffee Organization, 2019).

In Brazil, when there was over-production of coffee, the bean was used as

combustible fuel and fertilizer. The dried skin of the berry may also be used in making a

beverage. The pulp of the berry is used for preparing alcohol and as organic fertilizer in

the form of compost. Coffee pulp has been incorporated in animal rations. It contains raw

protein and nitrogen. It also has raw fibers, ash, K, Carbohydrates, fats and other organic

compounds such as caffeine and tannins (Bondad, 1984).

Freshly roasted and ground coffee can be used as deodorant, antiseptic and

germicide. An infusion will inhibit the growth of pathogens. A 10% infusion will kill anthrax

bacilli. During the 1825 cholera epidemic, physicians in New York found coffee every

effective against the spirillum of Asiatic cholera (Bondad, 1984).

Domestic Production

Philippine coffee production in dried berries was recorded at 17.16 thousand metric

tons, down by 6.9 percent compared with the previous year's level of 18.43 thousand
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metric tons. The leading producer of coffee for this quarter was SOCCSKSARGEN with

the production of 5.43 thousand metric tons or 31.7 percent of the total. It was followed by

the Davao Region and Northern Mindanao with respective shares of 14.0 and12.5 percent.

Among the types of coffee, Robusta coffee recorded the biggest production of 11.92

thousand metric tons or 69.4 percent of the total. It was followed by Arabica, 21.0 percent,

and Excelsa, 9.0 percent. Liberica type was the least produced, 0.6 percent (PSA, 2019).

Currently, the top 5 regions in producing coffee are Soccsksargen (Region 12) with

25,100.77 MT, Davao with 11,429.78 MT, Autonomous Region in Muslim Mindanao with

10,341.59 MT, Northern Mindanao with 5,604.95 MT, and Western Visayas with 4,356.25

MT (DTI, 2018).

Existing coffee roasting machines

Coffee Roasting Apparatus and Method

Patent 7143686 describes an industry coffee roaster that includes a combustion

chamber and roasting drum. The heating gases for the coffee beans recirculate through

the combustion chamber to remove the coffee bean chaff. Patent 7143686 is applicable

to Roasting Innovation’s design because it represents an alternative roasting drum design.

Coffee Roaster Drum Rocker Arm Roller Bearing System

Patent 7003897 describes an industry coffee roaster which includes a coffee

roaster drum and coffee roaster casing. The casing is fitted with bearings journals to allow

the drum to rotate horizontally. The invention also contains notch fittings to keep the drum

in place with the casing. This patent is applicable to the design because it represents a

way to control the thermal expansion. The patent specifies that industry roasters should

use cast iron while designing roasters; however, Roasting Innovation will use stainless

steel in its designs.

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Method and Apparatus for Roasting Coffee Beans

Patent 6036988 presents a small coffee roaster that uses heated airflow and drum

rotation to roast coffee. This patent is applicable to the design because airflow will be the

preferred way to heat the coffee beans and also alternative design on a roasting drum.

Fluidized Bed Coffee Roaster

Patent 5394623 describes a self-controlled coffee roaster which monitors the

coffee bean temperature. The roaster also injects water into the air stream to quench the

coffee beans when the roasting process is complete. This patent is applicable to the

design because it offers a different perspective to roasting coffee beans. Fluidized bed

systems allow for controlled mixing and heating because these systems insert small

amounts of the product instead of heating the entire product all at once.

Coffee Roasting Process and Apparatus

Patent 5287633 presents an industry coffee roaster that includes drum fins, shaft

bearings, and a gear motor. This patent is similar to the client's current product line and is

applicable to the design because it allows for insight into the advantages and

disadvantages of similar designs. This also would provide some insight on how to control

the thermal expansion of high-end industry coffee roasters.

Dual shaft pan mixer

Patent 4758095 uses dual shafts with attached paddle mixers. The shafts are

connected to a worm gear which is then powered by a motor. The paddles also contain

shovels that help mix the solids. The rotations of the shafts are opposite directions, while

the areas of sweep overlap each other. This patent shows how dual shaft mixers can be

used for food processing methods.

Coffee Roaster

Patent 4691447 presents a coffee roasting drum that rotates on a diagonal axis.

The roaster uses airflow to heat the coffee beans. This patent is applicable to the design
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because a diagonal axis drum allows for easy outlet flow. However, the heating of the

drum could be an issue for an industrial-sized roaster (Bolay, et.al, 2010).

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Definition of Terms

Cherry – the whole coffee berry that has not yet de-husked

and cannot be roasted directly.

Coffee Beans – the seed of the fruit that is called "cherries" due to

their bright red color that was dried and ready to be

roasted.

Efficiency – the total weight of roasted coffee beans is divided by

the total weight of coffee berries before loading

multiplied by 100.

Operating Time – the time when the coffee roaster machine performed

its actual roasting time from feeding to discharge.

Quality of Roasting - is based on the aroma, color/appearance, and taste

of roasted coffee beans after the roasting process.

Roasting – is a rapid cooking procedure of coffee beans in direct

or indirect heat that brings out the coffee flavor.

Running-in period - preliminary operation of the coffee roaster machine

to make various adjustments before the conduct of

the test until the operation stable.

Likert’s Scale - is a 5 point scale used to allow the respondents to

express their ideas about the quality of the roasted
coffee beans.

Tachometer – a device used for indicating the speed of rotation of

the shaft.
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METHODOLOGY

Duration and Location of the Study

The study was conducted in Visayan Village, Tagum City. The machine was

fabricated by a local fabricator, pre-tested and conducted from May to July 2018.

Procedural Framework

CONCEPTUALIZATION OF DESIGN AND SPECIFICATION

CONSTRUCTION OF COFFEE BEAN ROASTER

(FABRICATION)

PRETRIAL, TEST AND EVALUATION

DATA GATHERING

TABULATION OF RESULTS

ANALYSIS OF RESULT

REPORT AND WRITING

Figure 4. Procedural Framework.
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Conceptual Framework

As shown in Figure 4. Conceptual Framework of the Study, the independent

variable of the study is the coffee bean roaster machine which will be fabricated in

accordance with the dimensions and materials specified in the design plan. The efficiency,

capacity, and the quality are the dependent variables since it will be observed and

measured for changes that are thought to be caused by the changes in the independent

variable. The operator and temperature (roasting) itself is the intervening variable since it

can strengthen or weaken the independent and dependent variables and can affect the

overall performance of the designed coffee bean roaster.

INDEPENDENT DEPENDENT VARIABLES:

VARIABLE:  EFFICIENCY
 CAPACITY
 ROASTING TIME
 QUALITY
 ROASTING SPEED,
RPM


INTERVENING VARIABLES:

1. HUMAN FACTOR

2. TEMPERATURE

(ROASTING)

Figure 5. Conceptual Framework of the Research Study

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Conceptual Design

Figure 6. During Fabrication

Gathering of Materials

The following materials were used in the construction of a coffee bean roaster:

-1.2mmx4’x8’ stainless steel plate -2” diameter V-Belt Pulley

-G. I Sheet 1.2mm x4'x8' -3" diameter V-Belt Pulley

-1 cut Stainless Shafting 1" diameter x 24" -4" diameter V-Belt Pulley

-1/4 hp electric motor -1/8x1”x1”x20’ Angle Bar

-1 unit gear reducer (Ratio 1:40) -5” diameter V-Belt Pulley

-B66 V-Belt Pulley -Pillow Block Bearing lock type #206

-B58 V-Belt Pulley -Raw material peanut

- B58 V-Belt Pulley -Rice hull stove

-Bolts w/ nuts and washers (1/2 x 1 ½ and 3/8x 1 ½ )

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Instruments used during data gathering upon experimental procedure were:

- Digital Weighing Scale

- Data Sheet

- Pencil

Computation for Drumspeed

RPM (Roaster)

m
30 g 30 9.81 2
x √r =π x√ s
π 0.2032

30
= π
x 6.948205456

= 66.35 rpm - 25 = 41 rpm

Operating Procedure

The steps and procedures for the operation and data gathering on coffee bean roaster

are the following:

1. 1kg of Coffee bean (dried) to be roasted are native.

2. Measure the beans to get the initial weight. 9 kilograms were weighed using a

weighing scale. These served as a medium for the research study;

3. To start the operation, the engine was set to its assumed rpm by using a

tachometer and must preheat the roaster at the desired temperature.

4. For the first replication, 1 kilogram of coffee beans were loaded to the roaster.

5. After the roasting process, the capacity, efficiency, and quality must be evaluated.

6. Operations were repeated three times in every treatment in the same manner to

minimize the error of closure and to determine the average capacity, efficiency,

and performance of the prototype. If all the operations are done, the cleaning of
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the machine must be made to make it ready and available for the next operation

or run. Then it was stored it in a secure area.

Figure 7. Perspective view of the machine.

Testing and Evaluation

Pretesting

The fabricated design was pretested to ensure that the machine parts are

functional so the necessary redesign was made for the improvement of the device.

Testing

The fabricated design was tested to determine the capacity of the machine to roast

coffee beans and to know the ratio of the weights of the beans partially and roasted to the

weight of the input coffee beans.

Data Gathering

There was data gathering before, during and after the operation. For every

operation, three replications were done for each trial to get an accurate result. At the start
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of data gathering, the fabricated machine was checked to ensure its full function and

performance in the operation.

It was then followed by putting the fixed weight of the coffee beans into the

container, then starting and setting the rice hull stove to start the machine roasting

process. As soon as the operation started, time was set until the process was done. After

that, everything was set off and then removed the output coffee beans and placed it into

a sealed container. When the first trial ended, the process was repeated until all the

operations for each trial were done.

Preparation and Performance Evaluation

Testing

The fabricated design was tested to determine the efficiency of the machine to

roast and to know the ratio of the weights of the beans partially and totally roasted to the

weight of the input coffee beans. Following the proper procedures, 1 kg of coffee beans

were loaded and had been roasted for 30 minutes. As a result of the first trial, the output

product appearance was bad and could not satisfy a consumer in the market. Since the

result was not as good as expected, the researcher decided to extend the roasting time to

40 minutes for the second trial and repeated the operation. The result was noticeably a lot

better than the first trial and has a higher marketability potential.

FIRST TRIAL SECOND TRIAL

Figure 8. Preliminary Roasted beans
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Methods of Determining Roasting Efficiency

The primary consideration for determining the roasting efficiency in percent was

by weight basis. The weight of roasted coffee bean and weight of unroasted coffee bean

loaded together were measured in kilograms on a weighing scale. The total weight of

roasted beans is divided by the total weight of coffee berries before loading multiplied by

100.

Experimental Design

The experiment was conducted in Complete Randomized Design (CRD) with

three (3) treatments and three (3) replications. Each sample unit has a weight of 1kg

(kilogram). The study used factors namely: rpm (T1, T2, and T3) and roasting performance

as shown in Table 1.

Statistical Tool

Analysis of Variance was used as a statistical tool to test the significant difference

among treatments and the significant effect of the independent variables on the dependent

variables. The Tukey’s Studentized Range Test was applied in the study to compare the

significant effect among the treatments.

Table 1. Treatment and Performance Parameters

Replications
RPM
R1 R2 R3

𝑻𝟏 , = 22rpm T1R1 T1R2 T1R3

𝑻𝟐 , = 32rpm T2R1 T2R2 T2R3
𝑻𝟑, = 42rpm T3R1 TTR2 S3R3

Time= 40 minutes
 25

Calculation on Performance Evaluation

After the completion of roasting, the data were gathered and analyzed by the

following formulas that were used in calculating the different test analysis of the machine.

Roasting Efficiency of the machine

The roasted beans were weighed and the roasting efficiency was calculated as

follows:

RBt
RE= x 100
WBt
(Eqn. 1)
Where:

RE = Roasting efficiency

RBt = total weight of roasted beans, kg

WBt = total weight of coffee berries before loading

Sensory Evaluation

Sensory evaluation was done to evaluate the changes of the roasted coffee beans

as an effect of the given treatment. This was done with Likert's scale under the expertise

type of evaluation wherein only five (5) people with the necessary taste traits were

selected to act as respondents.

Table 2. Mean scale and the descriptive interpretation of the questionnaire.

Scale Descriptive Interpretation Qualitative
Description
In (%)
4.20 – 5.00 This means that the quality of roasted 81 -100
sampler is too high
3.40 – 4.19 This means that the quality of the roasted 61-80
sample is high
2.60 – 3.39 This means that the quality of the roasted 41-60
sample is moderate.
1.80 - 2.59 This means that the quality of the roasted 21-40
sample is low.
1 – 1.79 This means that the quality of the roasted 1-20
sample is very low.
 26

Economic Evaluation of Coffee Bean Roaster

The economic analysis of the coffee bean roaster will be performed in terms of the

Benefit-Cost Ratio (BCR). The parameters that must be considered are depreciation as

computed using the Straight Line Formula Method. The initial cost which includes the cost

materials and labor of construction, the savage value that is normally 10% of the initial

cost of the coffee bean roaster and the assumed 5 years life span of the storage.

(𝐼𝐶 − 𝑆𝑉)
𝐷=
𝐿𝑆

Where:

D= Depreciation Cost of the machine

IC= Investment Cost

SV= Salvage Value (10% of the Initial Cost)

LS= Lifespan of the machine (5 years)

Benefit-Cost Ratio

𝑁𝐼
𝐵𝐶𝑅 = 1 +
𝑇𝑂𝐶

Where:

BCR= Benefit-Cost Ratio

NI= the net income derived from the equipment

TOC= total operating time

To determine the net profit, the difference of the gross benefit and the total cost is

computed as follows:

Net Profit = Gross Benefit – Total Cost

The length of time required to recover the cost of an investment. The payback period of

a given investment of the project is an important determinant of whether to undertake the

 27

position project, as longer payback periods as typically not desirable for investment

positions.

Calculated:

Payback period = Cost of Project / Annual Cash Inflows

Rate of Return = Annual Net Profit / Capital Investment

 28

RESULTS AND DISCUSSIONS

Design, Fabrication and Performance Evaluation of a Coffee Bean Roaster

The whole structure of the coffee bean roaster was shown in the figure below. This

type of coffee bean roaster was made of materials that are readily available in the market.

It was powered by ¼ hp electric motor and can operate 8 hours a day, and can be cleaned

easily. Pre-testing of the roaster was done in order to find out that the machine parts are

functional so the necessary redesign was made for the improvement of the device.

PILLOW BLOCK
HOPPER/ EXHAUST

ROASTING CHAMBER
REDUCER
OUTLET
ELECTRIC MOTOR

RICE HULL STOVE

BELT

FRAME

Figure 9. Machine parts.

The Actual Roasting Operation

The coffee beans used in the operation were bought at the Tagum City Public

Market and its weight (kg) was determined by using a weighing scale. The operating time

was 40 minutes for every replication and was measured using a stopwatch.

The actual roasting operation during the collection of data is shown in figure 8.

There were three treatments and every treatment has three replications to minimize error.
 29

There was 9 kg of coffee beans used for the actual roasting operation using a coffee bean

roaster in different levels of rpm used and 1 kg of coffee beans in every operation. Different

levels of rpm were determined by the use of a tachometer.

Figure 9. The Actual Roasting Operation

Roasting Efficiency

Dried coffee beans loaded in the roaster recorded an initial weight of 1 kg.

Reduction of weight is mainly caused by the loss of moisture during roasting. The lighter

the weight of the roasted coffee after the process the more moisture was extracted. As the

amount of moisture removed was increased, the roasting efficiency of the roaster likewise

increased.

Table 3 shows the roasting efficiency of the coffee beans using the designed

roasting machine. Roasting efficiency was found out to be at 61.97% for 𝑻𝟏, 70.73% for

𝑻𝟐 and 82.70% for 𝑻𝟑. Treatment 1 indicates the most favored roasting efficiency due to

the fact that it recorded the lightest weight among the three treatments.
 30

Table 3. Roasting efficiency tested in three levels of rpm

Replication
Treatments __________________________________
Mean, %
1 2 3
Treatment 1
22 rpm 62.0 62.60 61.30 61.97
Treatment 2
32 rpm 73.0 76.20 63.0 72.73
Treatment 3
42 rpm 86.0 80.90 81.20 82.70

Statistical Interpretation of Data

The interpretation of the results using the statistical tool used in this study is one

factor Tukey's Test by the aid of ASSISTAT and these tests were based on the calculated

p-value of the data, with a 1% significance level (𝛼 = 0.01). If the p-value is equal to or

smaller than the significance level, there is a significant difference between the results

obtained. Moreover, if the p-value is less than .01, this means they are highly significant.

On the other hand, if the p-value is higher than the significance level, there is no significant

difference between the two or more obtained results.

The Appendix Table 1A shows the overall data collected through the experiment.

Using the ASSISTAT. The ASSISTAT reveals as shown in the Appendix table 2A that the

treatment three (3) having 42rpm yields a significant mean value of 82.70000. Treatments

one (1) the 22rpm (2) the 32rpm, both yields insignificant effect when compared to

treatment three (3); with a mean value of treatment one (1) 61.96667 and treatment two

(2) 70.7333.

The treatment three (3) had obtained higher results compared to treatment one (1) and

two (2) due to its high rpm because as RPM increases, beans fall off flights at higher

angles of rotation (Illy, A. and Viani, R. (1995)). Which means also that the moisture
 31

removed to the coffee beans during the process is not enormous, the beans were not

roasted well because the roasting speed, 42rpm was higher than computed rpm which

was 41rpm using the formula and since the roasting efficiency was computed based on

the total weight of roasted beans divided by the total weight of coffee beans before loading

multiplied by 100, the attained result was high. While the treatment one (1) and two (2)

resulted to be insignificant because their weight after the roasting process was lighter. The

moisture removed was higher which resulted in weight loss after roasting and lower

computed roasting efficiency.

The result was upturned because the lighter (weight) the product after the roasting

process, the more roasted it is and more efficient. Which means that the significant result

was treatments one (1) and treatment two (2) both having lower mean values compared

to treatment three (3) which yields the maximum.

Evaluation of Color/Appearance, Aroma, Taste of the Ground Coffee Beans

The color, aroma, and taste are the main requirements for determining the quality

of the roasted coffee beans. One missed requirement can affect the quality and price of

the product. The output product was tested and tasted by the experts who have knowledge

and experience about the coffee products at the University of Southeastern Philippines.

The researcher used Likert's scale by the use of the questionnaire to test the actual result

of the said quality. Appendix Table 3A was the result of the gathered data during the liquid

testing (Taste test) and 3B was the result of the dry test (Raw coffee powder) using the

questionnaire with a corresponding descriptive interpretation based on their mean scores.

The rating was the aroma, color/appearance, and taste. Each roasted coffee was

tasted and tested. In Appendix Table 5A Effect of roasting into the coffee based on the

mean score showed that the highest satisfaction rate of roasted coffee was treatment one

(1) having a score approximately 3.5 which denotes “the quality of roasted sample is high”
 32

that the product is great and it passed the panel of experts who conducted the test.

Treatment two (2) has a mean score of 3.05 which denotes “the quality of the roasted

sample is moderate" or acceptable and good enough but not as good as the treatment

one (1) though their mean scores are not that of great difference. Treatment three (3) have

an approximately 2.6 result which denotes “that the quality of the roasted sample is low”.

This explains that the quality of the roasted coffee is poor.

Treatments 1’s highest mean score could be justified by the result of the

computation using the formula for the drum speed. Horizontal-drum roasters have to rotate

with an RPM smaller than (30/π) (g/r), where g is the gravitational acceleration and r is

the drum radius (Illy, A. and Viani, R. (1995)).

Even though Treatment two (2) the 32rpm had a high result like the treatment one

(1) the 22rpm, it is still higher in rpm and it is closest to the computed rpm which was

41rpm using the drum speed formula.

Cost Estimate of a Coffee Bean Roaster

Cost estimate of the machine was computed using different parameters which

were investment cost, fixed cost, the variable cost, and gross income. Fixed cost

parameters include depreciation, interest on capital, taxes, and insurance while variable

cost parameters include: operation, repair and maintenance, lubrication and power

consumption (Barger, 1978).

Variable cost fluctuates directly with changes in output. The assumption rate for

an annual basis is 25 percent interest and capital, 10 percent repair, and maintenance, 6

percent for taxes and insurance of the investment (Viernes, 2005). The energy
 33

consumption was included in the variable cost since the coffee roaster machine used rice

hull stove.

Table 4. Cost and Return Estimate of Coffee bean roaster

Item Value
Investment Cost 15,980.00

Fixed Cost
Depreciation (5 years) 2876.4
Investment on Capital (25%) 3995
Tax and Insurance (6%) 958.8
Repair and Maintenance (10%) 1,598.0
TOTAL FIXED COST 9428.2
Variable Cost
Wages 56,700
Energy consumption&Fuel Cost (rice hull)
(Php 2394
9.00/kwhx0.1kwh/kgx1.5kg/hrx8hr/dayx180days/yr)
TOTAL VARIABLE COST 59,094
TOTAL OPERATING COST 84,502.2
GROSS BENEFIT 118,800
NET INCOME 34,297.8
Marginal Benefit-cost Ratio 1.40

A.) Depreciation Cost where: D= Depreciation

D= (IC – SV) / LS IC= Investment Cost

= (15980 – 1598) / 5 SV= Salvage Value

= Php2876.40 LS= Life Span

B.) Net Income

Energy consumption

Total Roasting Capacity= 1000g/40min

= 1.5 kg/hr.

Operation= 8hr/day @ 180 days/year

Rent of Machine= Php55.00 per kg of roasted coffee bean

Gross Benefit= (Php55/kg.1.5kg/hr.) x (8hr/day x 180 days/year)

= Php 118,800.00
 34

Net Income= 118,800 – 84,502.2

= Php34,297.8

C.) Marginal Benefit-Cost Ratio

BCR=Gross Benefit/Total Operating Cost

= 118,800/84,502.2

= 1.40
 35

SUMMARY, CONCLUSION, AND RECOMMENDATIONS

Coffee (Coffea sp.) is an economically important crop that contributes significantly

to the economy and serves as one of the major means of income for the livelihood of

coffee farming families.

Roasting coffee brings out the aroma and flavor that is locked inside the green

coffee beans. The coffee bean roaster study was designed, fabricated and conducted to

yield satisfactory roasting quality of coffee beans to help the small-scale coffee growers

reduce the time and effort of roasting their own product with poor quality which results in

uneven roasting or selling their unroasted coffee beans directly at a lower price.

The coffee beans were roasted having a 45–55% of moisture content. It was

roasted up to 10% to 12% of moisture content where the brittleness of the coffee required

in grinding, based on the farmer's rule of thumb, can be observed. The data gathered from

this study through roasting could be observed that the treatment one (1), having a result

of 61.96667, and treatment two (2) 70.7333, yielded the same effect compared to

treatment three (1) which had a significant result of 82.70000.

Of all the treatments, the treatments one (1) with 22rpm and two (2) with32 rpm

had a mean score of 3.5 and 3.05, respectively. That means that the quality of the coffee

sample given is high, it showed the highest efficiency level in dry testing (powdered coffee)

and liquid test (taste test) that were carefully evaluated by the respondents to ensure the

viability of the results. Treatment three (3) with 42rpm had a mean score of 2.6. This

means that the quality of the roasted sample is low.

Based on the result, we could identify the best RPM suitable in roasting Coffea sp

in the designed machine. Treatment 3 with 42 rpm, yielded the highest efficiency as shown

in Table 2A. Tukey's Standardized Range Test for Roasting Efficiency compared to

treatments 1 and 2 with 22 rpm and 32 rpm respectively.

 36

However, as we identified the effects of the treatment to its color, aroma, and taste,

by using the questionnaire it was determined that treatment 1 having 22 rpm obtained the

highest result having a mean score of 3.5 compared to treatment 2 having a mean score

of 3.05, and treatment 3 having a mean score of 2.6.

Having all of this, as a result, we can conclude that treatment one (1) having 22

rpm has the best effect in Coffea sp. when roasted using the designed coffee roaster

machine.

Based on the results of the study, the researcher would like to recommend the

following:

1. Improve the heat source (Rice hull stove) to be a more stable heat source like

putting it in a compartment type that can supply the required temperature and add

heat temperature sensor for a better outcome.

2. Modify the roaster’s speed. Use other alternatives to attain the rpm desired for the

study other than belt and pulley.

3. The discharge outlet for the roasted beans should be modified.

4. Compare the new data gathered to the previous one

5. Explore the roasting time ranging from 12 minutes to 30 if the temperature is

already steady and constant throughout the operation.

6. In sensory evaluation, the panel of experts that will test the coffee should be intact

in one place and will test it at the same time; also, do not put labels on the sample

to attain the more accurate result.

 37

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Encyclopedia 1986. Vol. 4 pp. 187-191.

BOLAY, K., HUBBARD, K., LOOKE, B., MARSHALL, M., MOYER, N., (2010). Roasting
Innovation. Design of a 300 Kilogram Coffee Roaster pp.10-12

COSTER, R. 1989. Coffee the Plant and the Product pp. 175-195

DELA CRUZ, R. 2007. bar.gov.ph, April-June 2007 Volume 9 Issue No. 2

DE WIT, J. 2005. Coffee Roasting Process pp. 5-7

DEROVIRA, D. 2006. The Flavor of Roasted Coffee pp.1

DEPARTMENT OF TRADE AND INDUSTRY (DTI). 2018. DTI SEES BRIGHT

PROSPECTS AHEAD FOR PHILIPPINE COFFEE INDUSTRY. Retrieved July 22,
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ILLY, A. and R. VIANI. (eds). 1995. Espresso Coffee. Academic Press, London, p. 96

ILLY, E. 2002 The Complexity of Coffee pp. 86-91

KELLY, E., and R. H. FOSTER. 1983. Processing and Storage of Foodgrains by Rural
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PASHLEY, T. 2017. Roaster Guide, Perfect Daily Grind

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Unpublished Undergraduate Thesis USeP- Tagum City p. 7

PHILIPPINE STATISTICS AUTHORITY (PSA). 2019. Major Non-Food and Industrial

Crops Quarterly Bulletin, January-March 2019. Retrieved July 22, 2019, from the
World Wide Web: (https://psa.gov.ph/).

TANGIDAY, W.H. 2008. Innovative Design of a Modified Portable Coffee Huller an

Unpublished Undergraduate Thesis USeP- Tagum City p. 1-8