Successful Commissioning of Instant Coffee Liquor 4-Effect Evaporator Upgrading Project in Indonesia

We are proud to announce the successful commissioning of an Instant Coffee Liquor 4-effect evaporator upgrading project in Indonesia. This project represents a significant achievement in enhancing evaporation efficiency, reducing energy consumption, and improving overall system reliability for instant coffee production.

Project Background

The project was designed to upgrade an existing evaporator system with the following objectives:

• Increase processing capacity

• Reduce specific steam consumption

• Improve operational stability under high-concentration conditions

With the growing demand for energy-efficient and high-performance processing systems in the food and beverage industry, this upgrade demonstrates our commitment to delivering practical and innovative engineering solutions, while also contributing to the reduction of carbon emissions and supporting more sustainable production practices.

Commissioning Challenges and Solutions

During the commissioning phase, several key technical challenges were identified and effectively resolved:

1. Vacuum Performance Limitations

Initial testing showed that the system vacuum could only reach -0.07 MPa, below the design requirement of -0.09 MPa. 

Through systematic inspection, leakage points at flange connections were identified and rectified, significantly improving system sealing and restoring vacuum performance.

2. Material Distribution Issues

The newly installed spiral distributor in the fourth effect experienced blockage due to the high content of insoluble solids in the coffee extract.

Following detailed analysis, the distribution system was redesigned by reverting to a distribution disc configuration, ensuring stable and uniform material flow.

3. High Solid Content and Fouling Risks

The process involves concentrating coffee extract from 4–5 Brix to approximately 45 Brix, resulting in a high level of insoluble substances and an increased tendency for fouling.

Operational strategies, such as increasing the recirculation flow rate, were implemented to mitigate scaling and prevent dry-heating risks. 

4. Foaming and Risk of Product Carryover

Instant coffee extract is prone to foaming during operation, which may lead to product carryover into the condensate system.

This issue was effectively controlled by maintaining proper liquid levels in each separator and ensuring timely discharge, thereby minimizing product loss.

Performance Improvements

Following the upgrade and optimization, the system achieved significant performance improvements:

1. Steam efficiency greatly increased

From approximately 2.0 tons of evaporation per ton of steam to ~3.9 tons per ton of steam

2. Vacuum performance restored

Achieving the design target of -0.09 MPa

3. Improved material distribution

Ensuring more stable and uniform operation

4. Enhanced operational reliability

Particularly under high-concentration and high solid-content conditions

Engineering Value

This project highlights the importance of combining process design expertise with hands-on commissioning experience. By addressing real operating conditions—such as material characteristics and system integrity—we delivered a solution that goes beyond theoretical design and achieves measurable, practical performance gains.

Conclusion

The successful commissioning of this project demonstrates our capability in delivering efficient, reliable, and customized evaporation solutions for the food and beverage industry.

We remain committed to helping our clients achieve higher efficiency, lower energy consumption, and more sustainable production through continuous innovation and engineering excellence.