Coffee is one of the most widely consumed beverages worldwide — second only to water. If every person on Earth drank coffee, global consumption would average 63 cups per person annually. Regional differences are striking: in 2020, for example, the average Italian consumed the equivalent of over 5 kg of coffee beans (Cibelli et al.).

While espresso and filter coffee still dominate, the coffee market is evolving rapidly. Segments such as fair-trade and especially instant coffee are experiencing strong growth.

One of the most energy-intensive steps in coffee production is roasting. After agriculture and packaging, it contributes the most to the carbon footprint of a cup of coffee. This was also highlighted by Gosalvitr et al., who assessed the life cycle costs of coffee production in the UK.

Additional studies, such as by Viana et al. in Canada, show that packaging methods —e.g. filter vs. capsule — have a surprisingly large impact, with capsules sometimes performing better environmentally. However, instant coffee still requires significantly more energy during production than ground coffee.

Since most of this energy is used to generate heat, the key question is: how can this heat be decarbonized?

Spoiler: in many cases, it’s surprisingly simple. For industrial-scale roasters, spray dryers, or steam-based processes, Kraftblock’s thermal energy storage system offers a highly effective way to use renewable electricity in coffee production.

This potential is being demonstrated in Kraftblock’s Volt Project with Eneco and PepsiCo, which focuses on electrifying and decarbonizing high-temperature processes in the food industry. The project is supported by the German Federal Ministry for Economic Affairs and Energy as part of the Renewable Energy Solutions Programme of the German Energy Solutions Initiative.

‍Process heat in coffee

WIn ground coffee production, the main heat-intensive step is roasting. This is typically done via direct gas flame or by heating air indirectly. In all roasting systems, hot gas or air is circulated around the green beans, transforming them into roasted coffee.

There are different roasting systems, including drum roasters, fluidized bed roasters, and centrifugal roasters. Regardless of type, temperatures range from 150 °C to 250 °C, and roasting usually takes 7 to 20 minutes, depending on the desired roast level.

This is where Kraftblock comes in: instead of fossil fuels, heat is generated from renewable electricity, stored, and supplied as needed. Especially for roasters that already operate with hot air, electrification is straightforward. Kraftblock’s storage system also enables:

• ‍Load shifting: electricity is stored when prices are low.
• ‍Operational flexibility: stored energy can be discharged according to production schedules.

Watch drum roasting in action from German Manufacturer Bühler.

Decaffeination and Instant Coffee Production

Before roasting, beans can be decaffeinated—usually using steam and mild solvents (Britannica). Here, too, Kraftblock’s system can supply steam from renewable sources, reducing emissions.

Instant coffee production adds further energy demand. After roasting and grinding, the coffee extract is spray dried — a process that atomizes liquid into droplets and dries them with hot air at 160–185 °C. Kraftblock’s hot air output can be used here as well, by simply adjusting the discharge temperature.

The Path Forward

Coffee production is energy-intensive, but electrification solutions are readily available. In regions with a high share of renewable energy, systems like Kraftblock are not only climate-friendly, but also cost-effective — especially when energy storage is used to optimize electricity purchases.

Kraftblock offers scalable solutions for industrial heat decarbonization — as seen in its work with PepsiCo and Eneco within the RES-Programme.

This project is supported by the German Federal Ministry for Economic Affairs and Energy as part of the Renewable Energy Solutions Programme of the German Energy Solutions Initiative.

Sources:

Piya Gosalvitr, Rosa M. Cuéllar-Franca, Robin Smith, Adisa Azapagic (2023): An environmental and economic sustainability assessment of coffee production in the UK. Chemical Engineering Journal, Volume 465 https://doi.org/10.1016/j.cej.2023.142793. (https://www.sciencedirect.com/science/article/pii/S1385894723015243)

Luciano Rodrigues Viana, Charles Marty, Jean-François Boucher, Pierre-Luc Dessureault (2023): Here’s how your cup of coffee contributes to climate change. Online: https://theconversation.com/heres-how-your-cup-of-coffee-contributes-to-climate-change-196648 

Matteo Cibelli, Alessio Cimini, Mauro Moresi (2021): Carbon Footprint of Different Coffee Brewing Methods. CHEMICAL ENGINEERING TRANSACTIONS VOL. 76, 2020. Online: https://www.aidic.it/eff2021/programma/54cibelli.pdf 

Britannica: How Is Coffee Decaffeinated? Online: https://www.britannica.com/story/how-is-coffee-decaffeinated#:~:text=The%20most%2Dcommon%20methods%20of,to%20flush%20away%20the%20caffeine.

VNT: Masteringthe Spray Drying Method for Instant Coffee: A Business Owner's Guide. Online: https://vinanhatrang.com/mastering-spray-dyring-method-for-instant-coffee/