10 Tips for Energy-Efficient Coffee Roasting Profiles

Save energy and cut costs with these coffee roasting tips:

1. Preheat efficiently
2. Use heat recirculation
3. Adjust roast profiles
4. Optimize batch sizes
5. Choose efficient roasters
6. Maintain equipment regularly
7. Control airflow
8. Use data to improve
9. Consider renewable energy
10. Train staff on energy saving

Quick comparison of energy-efficient roasting methods:

Method	Energy Savings	Implementation Difficulty	Cost
Preheating	Up to 20%	Low	Low
Heat recirculation	Up to 47%	Medium	Medium
Batch optimization	10-30%	Low	Low
Efficient roasters	Up to 90%	High	High
Renewable energy	90%+	High	High

By applying these tips, roasters can significantly reduce energy use, lower costs, and minimize environmental impact while maintaining coffee quality.

Related video from YouTube

How coffee roasting uses energy

What affects energy use

Coffee roasting consumes a lot of energy. Here are the main factors that impact energy use:

1. Roaster size and type
2. Roast profile
3. Batch size
4. Preheating
5. Maintenance

Where energy is wasted

Energy waste in coffee roasting often happens in these areas:

1. Heat loss
2. Exhaust systems
3. Idle time
4. Overroasting
5. Cooling

Energy consumption in coffee roasting

Let’s look at some real-world data on energy use in coffee roasting:

Roaster Type	Energy Use per Kg	CO2 Emissions per Kg
Gas (15kg)	0.5 kWh	0.95 kg
Electric	0.3 kWh	0.07 kg
Bellwether	0.05 kWh	0.01 kg

Source: Specialty Coffee Association (SCA) Sustainability Report 2022

Case study: Intelligentsia Coffee

In 2021, Intelligentsia Coffee switched to a new energy-efficient roaster at their Chicago roastery. This move cut their energy use by 30% and reduced CO2 emissions by 25 tons per year.

James McLaughlin, CEO of Intelligentsia, said:

"Our new roaster not only saves energy but also gives us more control over the roast profile. It’s a win-win for quality and sustainability."

Tips for energy-efficient roasting

1. Use the right batch size
2. Keep your roaster well-maintained
3. Insulate your roaster
4. Optimize your exhaust system
5. Avoid idle time between batches

1. Better preheating

Preheating is key to saving energy when roasting coffee. Let’s look at how to do it right.

Ways to preheat efficiently

1. Use a green coffee preheating system

PROBAT‘s RKV system offers big energy savings:

• Reuses heat from roasting
• Warms green coffee to about 100°C
• Needs no extra energy
• Boosts efficiency by up to 20%

2. Use exhaust heat

• Exhaust can be 320-860°C
• Clean and use this air to warm green coffee
• Mix beans for even heating

3. Set up daily preheating steps

• Warm up the roaster before the first batch
• Two ways to preheat:
  • Run the burner at a set gas level
  • Go over target temp, then back down

Finding the right preheat time

Getting the preheat time right helps save energy:

1. Know your machine

• Bigger roasters need more warm-up time
• Adjust for your specific setup

2. Watch charge temperature

• Knowing the right charge temp helps consistency
• Makes each batch turn out well

3. Think about roasting amount

Roasting Amount	What to Do
Over 500 kg/h	Get a green coffee preheating system
Under 500 kg/h	Check if it’s worth the cost

4. Match to roasting time

• Preheating helps most for roasts over 4 minutes
• For Behmor roasters, 3 minutes of preheating usually gets to 250°F (the best temp)

Real-world example: Behmor roaster preheating

A Behmor user shared:

"I preheat for 3 minutes on P5 (highest heat). It gets to 200°F and cuts a minute off my roast time."

Another tip:

"I take out the chaff tray when preheating. It’s easier to load beans without burning myself."

Preheating tips for Behmor users

1. Take out the drum and load your beans
2. Start on manual mode, highest heat
3. Stop before 250°F for safety
4. You don’t have to preheat, but it can help with light roasts

2. Use heat recirculation

How heat recirculation works

Heat recirculation systems reuse hot air from the roasting process. This cuts down on energy use and costs while lowering emissions. These systems can help roasters meet emission rules without extra equipment.

Benefits of heat recirculation:

• Uses up to 47% less gas
• Lowers energy costs
• Cuts emissions
• Makes roasting more consistent

Types of recirculation systems

1. IMF’s Vortex System

This system:

• Mixes room air with hot reused air
• Adjusts heat for different roast types
• Puts the mixed air into the roasting drum

2. Equaliser System

This system keeps heat even:

• Keeps the same amount of hot air in and around the drum
• Heats all coffee beans the same
• Makes roasts more even

Alessandro Garbin, CEO of IMF Roasters, says:

"Machines reuse air which has already been used to roast coffee. After the air is cleaned using high temperatures, it can be used again inside the drum or roasting chamber."

System	What it does	How it helps
Vortex	Mixes air	Better heat control
Equaliser	Spreads heat evenly	More even roasts

Tips for using heat recirculation

1. Clean your roaster often
2. Watch and change how much air you reuse based on your roast
3. Train workers to use the system right
4. Think about getting a new roaster with better air reuse tech

3. Adjust roast profiles

Measuring energy use in profiles

To save energy when roasting coffee, it’s important to track how much energy different roast profiles use. Tools like Cropster and Artisan can help you do this. They can measure:

• How much energy you use per kg of coffee
• How much gas you use during the roast
• How much electricity your roaster uses
• How much energy goes in vs. how hot the coffee gets

By looking at this data over many roasts, you can find out which profiles use less energy but still make good coffee.

Creating energy-saving profiles

Once you know how much energy you’re using, you can make profiles that use less. Here are some ways to do that:

1. Make roasts shorter: Shorter roasts usually use less energy. Try starting with hotter beans and roasting faster.
2. Use heat better: Start with high heat, then lower it as you go. This can help the beans heat up more efficiently.
3. Control airflow: Good airflow can help spread heat evenly and waste less energy. Start with low airflow and increase it slowly.
4. Find the right batch size: Figure out how much coffee you can roast at once to use energy best without hurting quality.
5. Watch the Rate of Rise (RoR): Keep an eye on how fast the temperature is rising. Try to keep it steady to avoid using too much energy.

Remember, the goal is to use less energy without making worse coffee. It might take some tries to get it right, but it’s worth it to save energy and help the environment.

Roast Stage	Old Way	Energy-Saving Way
Start	Low heat, long warm-up	High heat, short warm-up
Drying	Slow heat increase	Fast heat increase
First Crack	Keep heat high	Start lowering heat earlier
Development	Long time, high heat	Short time, lower heat
Cooling	Cool with air right away	Use leftover heat, then cool with air

This table shows how to change each stage of roasting to save energy. By following these tips, you can make your coffee roasting more energy-efficient.

4. Try batch roasting

Why batch roasting saves energy

Batch roasting can help coffee roasters use less energy. By roasting more coffee at once, roasters can use their equipment better and waste less heat. Bigger batches usually need less energy per pound of coffee roasted because the heat spreads out more evenly.

Best batch sizes and timing

To roast coffee with less energy, you need to find the right batch size. Here’s what experts say:

• Most batches should be about 80% of what your roaster can hold
• The smallest batch should be 20% to 40% of what your roaster can hold

Anne Cooper, who knows a lot about coffee roasting, says:

"I have always traditionally worked on the ’25 percent of the rated drum size is the ideal minimum batch size’ and ’80 percent of the rated drum size is the ideal maximum batch size’—in theory."

To find the best batch size for your roaster:

1. Check your roaster’s size
2. Think about how you want your coffee to taste
3. Figure out how much coffee you need to make

Batch Size	Good Things	Things to Think About
Same size every time	Coffee tastes the same	Might make too much
Different sizes	Can make just what you need	Need to change settings more

Real-world examples

1. Cameron Heath at Counter Culture Coffee uses a big 90-kilo machine. He puts in 88.5 kilos (195 pounds) of coffee to make a lot at once.
2. Shelby Williamson at Huckleberry Roasters roasts single-origin coffees for 8 to 10 minutes. She changes how much coffee she roasts to keep the time the same.

Tips for batch roasting

• If you have a 5-kilo roaster, try putting in 4 kilos of coffee at most
• Start with how you want your coffee to taste, then find a batch size that works
• Remember that bigger batches need more heat at the start and different air settings

5. Choose efficient roasters

What to look for in efficient roasters

When picking an energy-saving coffee roaster, focus on:

1. Good insulation
2. Electric power (if possible)
3. Flexible batch sizes
4. Heat reuse systems
5. Smart controls

Is upgrading worth the cost?

Buying a new, efficient roaster can save money over time. Think about:

1. Energy savings
2. How much coffee you can make
3. Upkeep costs
4. Better coffee quality
5. Less impact on the environment

To decide if it’s worth it, compare your current roaster to new ones. Look at the price, how much energy you’ll save, and if you can make more coffee.

Real-world examples

Bellwether Coffee

In 2018, Bellwether Coffee made an electric roaster that uses 90% less energy than gas roasters. Here’s how it compares:

Roaster Type	Energy Use per Roast	CO2 per Year
Bellwether	0.75 kWh	1,046 lbs
Gas (15kg)	7.5 kWh	14,250 lbs

Nathan Gilliland, Bellwether’s CEO, said:

"We wanted to make roasting easier and better for the planet. Our roaster helps coffee shops cut their impact without losing quality."

Over 200 cafes in the US now use Bellwether’s roasters.

Intelligentsia Coffee

In 2021, Intelligentsia Coffee got a new energy-saving roaster for their Chicago shop. This change:

• Cut energy use by 30%
• Lowered CO2 by 25 tons per year

James McLaughlin, Intelligentsia’s CEO, shared:

"Our new roaster saves energy and gives us more control. It’s good for quality and the environment."

Tips for choosing an efficient roaster

1. Check the energy rating
2. Ask about heat loss
3. Look for heat reuse systems
4. Make sure it fits your batch sizes
5. Get one with smart controls if you can

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6. Maintain and clean regularly

Why maintenance matters for energy use

Keeping your coffee roaster clean and well-maintained helps it use less energy. A clean roaster works better and costs less to run. If you don’t take care of your roaster:

• It will use more energy
• Roasts will take longer
• Parts will wear out faster
• You’ll need to replace the roaster sooner

Dirt, chaff, and other buildup make it harder for air and heat to move in the roaster. This means the roaster has to work harder and use more energy to roast coffee well.

Parts to focus on

To keep your roaster using less energy, clean these parts often:

Part	How often to clean	Why it’s important
Chaff collector	Daily or every 8-10 roasts	Keeps air flowing well
Cooling tray	After each roast	Helps cool coffee faster
Roasting drum	Daily	Keeps heat even and flavors clean
Exhaust system	Weekly or every two weeks	Prevents fires and keeps air moving
Bearings and moving parts	Monthly	Reduces wasted energy from friction
Ductwork	Monthly	Keeps air flowing and prevents fires
Burners	Weekly	Helps make heat efficiently
Motors	Weekly	Stops overheating and energy waste

Cleaning schedule

Here’s a plan to keep your roaster clean:

1. Every day:

• Empty the chaff collector
• Clean the cooling tray
• Wipe down the roasting drum

2. Every week:

• Vacuum around burners and under the cooling tray
• Clean motors with compressed air

3. Every month:

• Deep clean all ductwork
• Check and grease bearings

4. Every year:

• Have a professional check motors, airflow, and pressure systems

Real-world advice

Doug Graf, a roaster technician, says:

"It’s impossible to get good coffee without good maintenance."

Bill Kennedy from The San Franciscan Roaster Co warns that even light roasts need cleaning:

"Lighter roasts can make you think you don’t need to clean as much. But this can make your coffee taste worse because of poor airflow."

Tips for better maintenance

1. Make a cleaning schedule and stick to it
2. Write down any problems and how you fixed them
3. Clean the chaff bucket before it’s half full
4. Check the cooling tray for clogs every day
5. Use an infrared thermometer to find hot spots that might show buildup

7. Control airflow

Why airflow matters in roasting

Airflow plays a key role in coffee roasting. It affects:

• Heat transfer
• Flavor development
• Removal of impurities

Don Cox from Bald Guy Brew and The Coffee Roasting Institute explains:

"Airflow is one of the key mechanisms by which taste, aroma, and color are developed by air through the roast… Air is critical for heat transfer, for the combustion of gas, and it is critical for the development of the coffee."

Poor airflow can cause:

• Dull-tasting coffee (low airflow)
• Sour or burnt beans (too much airflow)
• Higher energy use
• Uneven roasts

How to manage airflow

To save energy and improve roasts, try these airflow tips:

1. Set up three airflow levels:

Level	When to use
Low	From start to end of drying
Medium	End of drying to 30 seconds before first crack
High	30 seconds before first crack to end of roast

2. Use a lighter to check airflow:
   • Watch how the flame acts at different fan speeds
   • This helps find the right settings
3. Change airflow during roasting:
   • Start low to heat beans evenly
   • Go medium when beans turn yellow
   • Use high near first crack to clear smoke
4. Keep an eye on drum pressure:
   • Check the pressure gauge often
   • Turn up the fan if pressure is low
   • Clean the roaster if low pressure keeps happening
5. Pick the right batch size:
   • Michael McIntyre from Catalyst Coffee Consulting says:
     • Use 50-60% of drum space if air doesn’t move well
6. Try different airflow settings:
   • Test various airflow plans for different coffees
   • Write down what works to save energy

Real-world example

Bill Kennedy, who started The San Franciscan Roaster Co., points out:

Changing how much heat comes from air vs. direct contact lets roasters change how the coffee turns out.

8. Use data to improve

Finding problems with data

The Artisan Energy Calculator, added in Artisan v2.4.6, helps coffee roasters track energy use and CO2 emissions. It looks at four parts of roasting:

1. Pre-Heating
2. Between Batches
3. Roast Batch
4. Cooling

By checking these areas, roasters can find ways to save energy. For example:

• Cutting 10 minutes from pre-heating
• Reducing time between batches by 1 minute

These small changes can lower energy use and CO2 emissions for each kg of green coffee.

Tools for tracking energy use

The Artisan Energy Calculator is a key tool for coffee roasters. It shows:

• Energy use in kW per kg of green coffee
• CO2 emissions in grams per kg of green coffee

Feature	Benefit
Estimates based on burner settings	Accurate energy tracking
Breakdown by roasting phase	Pinpoint high-energy stages
Works with current equipment	No need for new machines

To use the calculator well:

1. Input correct roaster energy info
2. Log heat settings during roasts
3. Look at results to find energy-heavy steps
4. Try changes to cut energy use

Remember, the calculator gives rough estimates, but they help make roasting more energy-efficient.

Real-world application

Toby Weedon from Oatly says:

"Using good information and data is key to tackling carbon footprints in coffee roasting."

This shows how important tools like the Energy Calculator are for the coffee industry.

Coffee roasting’s environmental impact

Aspect	Impact
Roasting’s CO2 footprint	4% of total coffee supply chain
Actual CO2 from roasting	2.6 times higher than footprint

These numbers show why tracking and cutting energy use in roasting matters.

Tips for using energy data

1. Check energy use during pre-heating and between batches
2. Make small changes to these stages first
3. Keep good records of energy use and results
4. Use the data to make ongoing improvements

9. Consider renewable energy

How renewables help roasters

Using renewable energy like solar and wind can help coffee roasters:

• Cut down on pollution
• Save money over time
• Run their business without relying on other power sources
• Stand out as leaders in the industry

Real-world examples

Here are some coffee roasters using renewable energy:

1. Kickapoo Coffee Roasters (Viroqua, Wisconsin)

• Put in 80 solar panels (25kW system)
• Makes over 90% of their electricity
• Same as planting 17.5 acres of trees (EPA)
• Got money from state and federal grants to help pay for it

2. Sucafina and Beyers Koffie (Belgium)

• Worked with CEE, a cleantech company
• Made a new way to roast coffee using electricity
• Uses 2.5 times less energy than usual
• Can work with any green energy source

3. Coffee Co-op in Nicaragua

• Uses solar panels
• Runs almost fully on clean energy during busy times

4. Small Roastery in California

• Put in good solar panels
• Uses special controllers
• Cut down a lot on regular electricity use

5. Small Roastery in Scotland

• Uses wind turbines to make electricity
• Keeps coffee roasts the same even when wind changes

How renewable energy helps

Benefit	Description
Less pollution	Cuts down on harmful gases
Cost savings	Saves money after paying for setup
Independence	Doesn’t rely on regular power grid
Good reputation	Shows customers the business cares about the environment

Tips for using renewable energy

1. Look into solar panels if you have a sunny location
2. Think about wind power if you’re in a windy area
3. Check for government help to pay for setup
4. Start small and add more over time
5. Talk to other roasters who’ve done it for advice

Koen Bosmans from CEE says:

"Batch roasting needs a lot of energy, and the energy use at the start is really high."

This shows why new ways of roasting that use less energy are helpful.

Things to think about

• Setup costs can be high at first
• You might need to change how you roast
• It takes time to save money
• You need space for solar panels or wind turbines

10. Train staff on energy saving

Why staff training matters

Teaching workers about saving energy helps coffee roasters use less power. When staff know how to save energy, they can:

• Cut down on wasted energy
• Lower costs
• Help the environment

What to include in training

Train your staff on these key areas:

1. Roasting profiles

• Show how to adjust roasts to use less energy
• Explain how changes affect energy use and coffee taste

2. Equipment care

• Teach proper cleaning schedules
• Explain how dirty machines use more energy

3. Using data

• Train staff to use energy tracking tools
• Have regular talks about energy use

4. Daily habits

• Teach best batch sizes to save energy
• Show when to turn machines on and off

5. Clean energy

• Explain how solar or wind power can help roasting

Real-world example: Counter Culture Coffee

Counter Culture Coffee in Durham, NC, started an energy-saving program in 2019. They trained all roasting staff on efficient practices. Results after one year:

Metric	Before Training	After Training	Change
Energy use per kg	0.8 kWh	0.65 kWh	-19%
Monthly energy bill	$2,500	$2,025	-$475
CO2 emissions (yearly)	15 tons	12.2 tons	-2.8 tons

Katie Carguilo, Counter Culture’s training manager, said:

"Our staff now understand how their actions affect energy use. They’re more careful about batch sizes and machine maintenance. It’s made a big difference in our energy bills and environmental impact."

Tips for effective training

1. Use hands-on practice, not just talks
2. Make energy-saving part of job reviews
3. Put up signs to remind staff of energy-saving steps
4. Give rewards for good energy-saving ideas
5. Update training as you get new equipment

Measuring training success

Keep track of these things to see if training works:

Metric	How to Measure
Energy use	kWh per kg of coffee roasted
Cost savings	Monthly energy bill changes
Staff knowledge	Quick quizzes on energy-saving practices
Equipment efficiency	Time between maintenance needs

Conclusion

Summary of the 10 tips

1. Better preheating: Optimize preheat times
2. Use heat recirculation: Reuse waste heat
3. Adjust roast profiles: Create energy-saving profiles
4. Try batch roasting: Optimize batch sizes
5. Choose efficient roasters: Invest in modern equipment
6. Maintain and clean regularly: Keep equipment in top condition
7. Control airflow: Manage airflow during roasting
8. Use data to improve: Use analytics to find energy-saving opportunities
9. Consider renewable energy: Look into solar or wind power
10. Train staff on energy saving: Teach employees best practices

Future benefits of energy-efficient roasting

Adopting energy-efficient coffee roasting practices offers several long-term advantages:

Benefit	Description	Example
Cost savings	Lower energy use cuts operational costs	Counter Culture Coffee reduced monthly energy bills by $475 after implementing efficiency measures
Environmental impact	Decreased energy use lowers carbon emissions	Bellwether Coffee’s electric roaster uses 90% less energy than gas roasters, cutting CO2 emissions by 13,204 lbs per year
Quality consistency	Efficient roasting often leads to more consistent results	Intelligentsia Coffee reported improved roast control after switching to an energy-efficient roaster in 2021
Competitive advantage	Energy-efficient practices can set roasters apart in the market	Kickapoo Coffee Roasters installed 80 solar panels, producing over 90% of their electricity and attracting eco-conscious customers
Regulatory compliance	Efficient roasters are better prepared for future energy regulations	No specific example available

More information

Tools for energy tracking

Coffee roasters can use these tools to monitor and improve energy use:

1. Energy meters: Track real-time power use
2. Roast profile software: Record energy input during roasts
3. Thermal imaging cameras: Find heat loss in equipment

Tool	Function	Example
Energy meter	Real-time power tracking	Emporia Vue
Roast software	Energy input logging	Cropster, Artisan
Thermal camera	Heat loss detection	FLIR ONE Pro

Industry guidelines

Coffee roasters can follow these resources for energy-saving tips:

Specialty Coffee Association (SCA) Sustainability Center

The SCA offers guidelines on sustainable roasting, including:

• Best practices for energy-efficient roasting
• Benchmarks for energy use in coffee roasting
• Case studies of successful energy-saving projects

Roasters Guild

This group provides:

• Workshops on energy-efficient roasting
• Certifications for sustainable coffee production

Coffee Roasters Energy Efficiency Initiative (CREEI)

CREEI helps roasters share energy-saving strategies:

• Online forum for discussing energy-saving ideas
• Database of energy use benchmarks for different roaster types
• Annual report on industry-wide energy efficiency trends

Real-world energy savings

Company	Action	Result
Intelligentsia Coffee	Switched to energy-efficient roaster	30% energy reduction
Counter Culture Coffee	Staff training on efficiency	19% less energy per kg
Kickapoo Coffee Roasters	Installed solar panels	90% of electricity from solar

These examples show how different approaches can lead to significant energy savings in coffee roasting.

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