Automated transfer and packaging of green coffee

The client, an industrial player in the coffee processing sector, wanted to automate and secure the reception, transfer and packaging of green coffee beans at its production site.

The main objective was to have a complete line capable of processing different varieties of green coffee while ensuring perfect batch traceability from reception to final storage.

One of the major challenges of the project was managing the diversity of coffee formats (from several origins) and the need to limit cross-contamination between batches.

The customer wanted to integrate an efficient cleaning system, particularly for the hoppers and transfer equipment, to ensure rapid recipe changeover without residue.

The installation also had to allow precise control of the flow and quality of the beans transferred to the packaging units, while reducing operator exposure to dust and handling.

The system had to be flexible and scalable, capable of adapting to future regulatory traceability requirements and market developments, particularly in the preparation of new formats such as ground coffee and functional mushroom-based powders.

To meet the customer's technical requirements, Palamatic Process designed a complete line dedicated to the processing of green coffee, incorporating customised equipment to ensure automatic, hygienic and traceable transfer of the beans from reception to packaging.

The line begins with a receiving hopper equipped with a high-capacity dust removal system (up to 2,000 m³/h) that captures volatile particles as soon as they are unloaded.

This hopper is designed with an anti-abrasive inner coating and a 62° slope, ensuring optimal flow of the beans, even when the coffee has a high moisture content.

An EasyFlow® big bag emptying system is integrated, with a suspension cross, a vibrating plate mounted on silent blocks, a sealing skirt and a safety screen.

This module allows for rapid and safe deconditioning of big bags, while ensuring that no foreign bodies enter the material flow.

Mechanical transfer is provided by a 304L stainless steel tubular screw with a diameter of 273 mm, capable of maintaining a constant flow rate of 12 m³/h over a distance of 20 metres.

The direct drive motorisation system saves energy and facilitates cleaning thanks to quick access to the parts in contact with the product.

To meet traceability requirements, each batch is assigned an identifier via RFID sensors connected to the Pal'Touch® automation system.

This system enables real-time production monitoring and batch data archiving, ensuring full compliance with food safety standards.

An automatic cleaning airlock (CIP) has been installed in line to enable rapid rinsing of critical areas, including the transfer screw, buffer hopper and connection areas.

This module uses high-pressure rotating nozzles (120 bar, 15 l/min), ensuring effective cleaning between batches.

Finally, the solution includes a dosing buffer hopper, mounted on load cells with ±0.5% weight flow control, enabling precise filling of storage containers or roasting units.

1. Receiving hopper with integrated dust extraction

Designed for direct unloading of green coffee, this 1,500 litre hopper is equipped with a dust extraction ring and a variable flow air extractor (up to 2,000 m³/h).

The 62° slope discharge cone ensures that the beans flow without stagnation, limiting clogging.

The interior surface is treated to prevent abrasion and preserve the integrity of the beans.

2. EasyFlow® big bag emptying station

The standard EasyFlow® station with hoist loading includes:

• 5-point handling cross (2 tonne capacity)
• Sealing skirt for containment
• Motorised vibrating tray to promote flow
• Stainless steel DN250 safety screen
• Overflow tube to control the flow of grains

This assembly guarantees ergonomic, hygienic and safe emptying, compatible with all types of big bags.

3. Tubular transfer screw

A 304L stainless steel transfer screw, 273 mm in diameter, equipped with welded helical blades and a direct drive motor, transports the grains to the buffer hopper.

The system can operate continuously at a nominal flow rate of 12 m³/h and supports lengths of up to 18 metres with intermediate bearings.

4. Dosing buffer hopper

Mounted on weight control scales, this hopper allows precise dosing to the packaging or roasting units.

It includes:

• Guillotine valve for flow regulation
• Weighing sensors with ±0.5% accuracy
• Useful volume: 600 litres

5. Cleaning in place (CIP) module

The CIP cleaning system includes:

• High-pressure rotary nozzles (15 l/min at 120 bar)
• Recovery and rinsing tanks
• Automatic programming via Pal'Touch®

This module allows rapid cleaning of critical parts, reducing downtime and ensuring no residue between batches.

6. Pal'Touch® automation

The entire process is controlled by the Pal'Touch® system, equipped with:

• Siemens ET200 SP touch screen
• RFID batch tracking and traceability
• Intuitive multilingual interface
• Production history archiving