With margins and cash flow stretched thin, a machine that just roasts coffee is no longer enough; today’s roasters are increasingly demanding more from their equipment. They’re looking for systems equipped with high-performing software and technology, as well as comprehensive support, to help improve quality, streamline operations, and reduce costs.

I spoke to Doug Hewitt at 1951 Coffee Company and Gabriel Boscana at Bellwether Coffee to learn how new demands from roasters have influenced roasting technology and the services that manufacturers offer.

You may also like our article on how to start a microroastery.

Roasters are facing new challenges

Coffee roasters are under more pressure than ever, especially due to rising costs across the entire value chain. Green coffee prices have more than doubled over the last year. In 2024, arabica futures increased 70% to their highest levels since 1977, while robusta prices reached all-time highs.

These price surges stem from low crop yields in Brazil and Vietnam, growing uncertainty surrounding the EU’s impending deforestation regulations, and logistical disruptions, such as the temporary closure of ports in Djibouti, a key transit point for Ethiopian coffee.

In response, more coffee businesses are exploring in-house roasting as a way to regain control over quality, pricing, and sourcing. To support this trend, Bellwether Coffee, which will exhibit at WoC Geneva at booth #1422, created an ROI Calculator to help retailers analyse the costs and benefits of roasting their own coffee.

Price volatility has continued into 2025, with the new floor for the C market now estimated at around US $4/lb. Inflated pricing has left many coffee roasters with shrinking cash reserves, making it difficult for them to continue operations as usual. 

Roasters who haven’t hedged their coffee purchases, locking in prices ahead of time, are especially vulnerable to sharp price increases. While larger roasters are somewhat protected by scale and buying power, the price hike is more concerning for smaller roasters that can’t buy in bulk and operate on a shorter-term basis.

Logistical hurdles persist

Rising costs across the board, including transport, storage, and energy, exacerbate the situation. Freight rates have surged, warehousing expenses are up as roasters are forced to hold onto inventory for longer, and tariffs in countries like the US have increased significantly. 

For example, the US currently has a 10% “baseline” tariff on almost all imports. Some countries (including major coffee-producing nations like Vietnam and Indonesia) are potentially facing even higher rates, despite the lack of a domestic alternative. As a result, US roasters are likely to pay anywhere from 10% to 35% more for green coffee. 

Energy costs are also expected to rise by 7% in the US and other regions, while global inflation rates have remained high since the pandemic. Most roasters can’t afford to absorb these increased costs, and are considering retail price hikes and rethinking their sourcing strategies to stay competitive.

A growing demand for more than just a roasting machine

Roasters typically operate on tight margins for a few reasons, including high (and volatile) green coffee prices, rising operational costs, and the need for highly specialised equipment.

Coffee roasting equipment, in particular, is a significant investment, and with costs rising, the decision to purchase a new machine is more crucial than ever.

“The Bellwether Shop Roaster, for example, is an all-electric, ventless, and automatic countertop machine that doesn’t require gas lines or construction,” says Gabriel Boscana, a green coffee buyer at Bellwether Coffee. “It can roast up to 1.5kg per batch, with three to four roasts per hour. This means you can roast 20 kg in up to 4.5 hours, allowing for even greater daily output depending on how long you operate the roaster.

To cope with additional pressures, many roasters are no longer interested in machines that only roast – they want modern systems that offer advanced software and technology, as well as unique features that support their entire roasting operations.

“With the Continuous Roasting Upgrade, you can load enough green coffee for up to 13 consecutive batches,” Gabriel adds. “In under 4.5 hours, the machine can roast 20kg of coffee with no intervention – just unload the roasted coffee and reload green coffee for another cycle. In a standard nine-hour shift, you could roast up to 40kg with only a few minutes of labour required.”

“We only had to install a new plug receptacle in the café, and we were ready to go,” says Doug Hewitt, the CEO of 1951 Coffee Company, a roaster in Berkeley, California that supports refugees with access to barista training programmes. “It was easy to find space to place the roaster, and we didn’t have to worry about permits to install ventilation. It takes up to two minutes of manual labour to set up a roast.”

The push for greater sustainability in roasting 

Today’s consumers are increasingly choosing to support brands that prioritise sustainability. When it comes to coffee, 43% of consumers say their choices are influenced by “ethical, environmentally friendly, or socially responsible options”.

However, the worsening climate crisis poses a threat to the future of the coffee value chain. The Intergovernmental Panel on Climate Change (IPCC) warns that nearly half of the world’s coffee-growing land could become unproductive by 2050, with yields dropping as much as 70%.

Coffee roasting is a known contributor to this problem. Traditional gas-powered roasters release significant amounts of carbon dioxide, methane, and other volatile organic compounds (VOCs) that contribute to global warming.

Given the growing consumer demand for sustainability and the looming climate crisis, coffee roasters must seriously consider the environmental impact of their equipment.

For instance, all-electric machines, like Bellwether, can reduce a roaster’s carbon footprint by up to 87% compared to gas-powered systems.

“As a nonprofit social enterprise working with immigrants, we know that climate change is one of the main driving factors in human migration and global conflicts,” Doug says. “Being able to minimise our impact on global warming is essential to our overall mission.”

Doug adds that 1951 Coffee Company is 100% solar-powered and emphasises that Bellwether’s low-emission roaster helps reduce the company’s carbon footprint.

Adopting more eco-friendly practices isn’t just positive for the environment, but it’s also an effective cost-saving measure. Electric roasters can reduce waste and eliminate fuel costs, helping pad roasters’ bottom lines.

New levels of support for coffee roasters beyond equipment

As roasters increasingly demand more from their machines, modern coffee roasting equipment now incorporates additional features to make sourcing and roasting high-quality coffee more accessible.

For example, Bellwether’s Roast Manager consolidates roasting operations across multiple locations into one cloud-connected interface. Roasters can use this platform to create, clone, and customise roast profiles, analyse roast history, access a library of support resources, and review maintenance tasks.

“I have used the Roast Manager to monitor the amounts of each type of coffee we roast, machine operations, and troubleshooting,” explains Doug. “I often get pulled in a lot of directions, but being able to respond to team inquiries with up-to-date information anywhere I am is helpful.”

Another support feature roasters can leverage is Bellwether’s Green Coffee Marketplace, which helps roasters source high-quality green coffee lots and provides pre-developed roast profiles tailored to each coffee.

“The Shop Roaster itself is easy to use and intuitive, and we guide customers through the process from green coffee selection from our marketplace to profiling the roasted product,” says Gabriel.

“We offer profile suggestions and full traceability of the coffees available on the marketplace,” he adds. “We also provide suggestions as to which coffees to start the roasting journey with and how they might work in blends.”

The platform also supports ethical sourcing through Bellwether’s Living Income Pricing, which pays producers 50% more than Fairtrade coffee prices and 78% more than commodity prices. Roasters, in turn, gain farm-to-cup transparency, ensuring higher standards for farmer equity.

“A small company like ours doesn’t have the resources to put toward a green coffee buyer or the time to travel to farms to build relationships and know that we’re sourcing quality coffee with a positive impact on producing communities,” says Doug. “Instead, we have to rely on the stories and details about the producing communities so we can research and see the impact our coffee purchases are making.”

How modern solutions are supporting roasters

As coffee roasters continue to grapple with rising costs and customers become increasingly price-conscious, they must balance cost-cutting measures without compromising on quality or flavour.

Fortunately, new roasting technologies are making this task easier to achieve, helping roasters improve quality and streamline operations, both of which mitigate the effects of increased costs.

By utilising integrated roasting systems, roasters can reduce overhead costs, closely manage their supply chain, and gain greater control over their coffee quality. The Bellwether Marketplace, for instance, enables roasters to purchase 10kg (24lb) boxes or full bags of green coffee through direct trade. 

“Roast profiles are built in, which saves roasters from spending time tweaking their recipes and going through bags of green coffee, which is another expense,” explains Gabriel. “Especially now, with all costs becoming more expensive, controlling the cost of your raw material is a huge boost to a brand and business.”

Doug notes that in-house roasting has helped him reduce waste and improve inventory management. Bellwether’s ROI calculator enables coffee business operators to better understand the costs and benefits of in-store roasting.

“When we were a wholesale account, we always had to try and predict the ebbs and flows of business, but always seemed to have some coffee that would be reaching the end of its quality date,” he says. “Roasting coffee ourselves allows us to have wholesale and online retail options to keep inventory moving and refreshed.”

Modern roasting systems also offer automated features that help free up staff and reduce human errors, minimising waste and labour costs. For example, the Shop Roaster’s Continuous Roasting Upgrade includes a green coffee autoloader with a 20kg capacity and a storage base for roasted coffee. These features help boost productivity by allowing staff to focus on other tasks, rather than constantly monitoring the machine.

As costs continue to rise across every part of the coffee supply chain, staying profitable is becoming harder, especially for roasters already operating on razor-thin margins. In today’s climate, roasters will continue to seek out equipment that goes beyond just roasting coffee to combat this.

Looking ahead, we can expect to see a rise in roasting systems that offer greater sustainability, automated features, and support that extends beyond the machine itself.

These advancements won’t just help roasters weather tough conditions; they’ll also allow roasters to effectively cut costs, maintain high-quality standards, and build more efficient and scalable roasting operations.

Enjoyed this? Then read our article on how micro roasters paved the way for in-store roasting.

Photo credits: Bellwether Coffee

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As such, a passion for coffee quality and traceability is essential to starting a successful micro roastery. However, operators also need to take a pragmatic approach to managing margins and cost efficiency – especially while business costs and coffee prices are rising.

To learn more, I spoke to Donovan Albert, the owner and CEO of Anchor & Tree Coffee Roasting Co. in California, US, about how the company has used Bellwether Coffee machines to scale.

You may also like our article on how micro roasters paved the way for in-store roasting.

What are the first steps when opening a micro roastery? 

“Micro roasting has become incredibly popular in recent years primarily due to the ability to control the outcome by roasting coffee in smaller batches,” says Donovan Albert, the owner and CEO of Anchor & Tree Coffee Roasting Co. in Sacramento, California. “You can control the heat application more precisely, offering more consistent flavour profiles and reducing the variables within the batches.”

These coffee offerings provided customers with something new and offered roasters a point of differentiation in an increasingly competitive market. But when choosing to start a micro roastery or roast coffee in-store, decisions can quickly become overwhelming, so it’s important to address some of the essentials first.

“The first thing to think about is finding a machine that aligns with your mission and long-term goals,” Donovan explains. “You need to find a roaster that you have the knowledge base for, and that will allow you to roast the types of coffee that you want.”

Today’s coffee consumers are increasingly looking for businesses that prioritise sustainability. According to a recent study from the International Institute for Sustainable Development, 43% of coffee consumers say they are influenced by “ethical, environmentally friendly, or socially responsible coffee options”, meaning businesses have an opportunity to tap into growing demand and differentiate themselves. 

From packaging to green coffee buying to roastery operations, more coffee companies than ever are claiming their practices and products place environmental, social, and economic responsibilities at the forefront.

Even more pertinently, the worsening climate crisis is having a growing impact on the coffee value chain. By 2050, the amount of land available to grow high-quality arabica is estimated to halve, threatening the future of the industry as we know it. 

This makes the equipment you choose, which contributes to the industry’s carbon emissions, all the more important. Donovan says all-electric roasters like Bellwether can reduce roasters’ carbon footprint by up to 87% compared to gas-powered alternatives. Additionally, the Bellwether Green Coffee Marketplace gives them access to ethically sourced, transparently traded green coffee – eliminating the guesswork from responsible sourcing.

“I wanted a roaster that was sustainable and eco-friendly without compromising the quality of our coffee,” Donovan tells me. “With my background in roasting software education, I felt like the Bellwether Shop Roaster was a perfect fit; it’s electric, ventless, automatic, and eliminates up to 90% of carbon emissions from the roasting process.”

Sustainability isn’t just an environmental concern; it’s also a cost-saving measure. With electric machines, roasters can eliminate fuel costs, reduce waste, and streamline operations, all of which contribute to a healthier bottom line.

Scaling a micro roastery for long-term business growth

Micro roasters must maintain consistency and remain true to their value proposition to ensure consumer loyalty, presenting ongoing challenges. Looking ahead, scaling operations can also pose a major hurdle to navigate.

To overcome this, it’s important to set realistic goals and have a clear vision of what the business wants to achieve in a given time frame. Some questions for owners and operators to consider include:

• Do you want to take on wholesale clients?
• Is it a goal to branch out and open multiple outlets in the same city or across various geographies?
• Do you eventually want to increase roasting capacity and move to a larger commercial space?

“Everything won’t work the way you want it to at first, so being patient is extremely important,” Donovon says. “Hone in on one side of the business first instead of stretching yourself thin, focusing on many different things at the same time.”

Wholesale roasted coffee can cost up to 50% more than roasting in-house. Businesses that invest in their own roasting equipment not only control their costs but also open up new revenue streams, such as wholesale accounts and private-label offerings.

“If you’re new to roasting, I would first recommend finding a co-roasting space to learn as much as you can and take roasting classes,” Donovan adds. “This will help you decide what type of roaster you want to become and what type of coffees you want to sell.”

Choosing the right roasting equipment for efficiency & growth

One of the key considerations for micro roasters is selecting equipment that can grow with their business. Many small-batch roasters start with a traditional gas roaster, only to realise that scaling requires additional infrastructure like gas lines, staffing, and operational complexity. 

Donovan says the Bellwether Shop Roaster, awarded Best New Product by the Specialty Coffee Association at World of Coffee Copenhagen in June 2024, eliminates these challenges with its electric, ventless, and fully automated design.

He adds that the Countertop Roaster has a 1.5kg capacity per batch and can roast up to four batches per hour, making it ideal for small-scale, on-demand roasting. The Continuous Roasting Upgrade, meanwhile, has an autoloading system capable of roasting up to 200kg (440lbs) per week, offering up to 13 continuous roasts, allowing businesses to scale volumes should they choose to.

“The Shop Roaster’s continuous roasting option allows me to free up my bandwidth to focus on other tasks, removing the need for constant monitoring and intervention,” Donovan adds. “It’s been a game-changer for our business growth.”

Streamlining operations has never been more important for coffee businesses looking to scale or maintain current roasting volumes. With a high and volatile C price, rising inflation, and growing interest rates all squeezing already-thin margins, roasters are being pushed to manage costs more effectively than ever before.

Automation has emerged as a viable way for operators to replicate human-driven processes that free up time and reduce error, minimising costs in the long run. For example, the Bellwether Shop Roaster’s Continuous Roasting Upgrade features a green coffee autoloader and freestanding base roasted coffee storage unit, allowing roasters to increase productivity without increasing labour costs.

Why equipment plays an integral role in growth

Smaller batch sizes can help micro roasters offer more variety to their customers, allowing operators to switch between different coffees quickly. However, at the same time, micro roasters may seek to scale operations in the future, and their equipment needs to account for this.

Donovan explains that machines like Bellwether allow micro roasters to expand efficiently without increasing overhead. The Continuous Roasting Upgrade means businesses can meet demand while keeping roasting time to a minimum. Additionally, cost savings from in-house roasting create new opportunities, such as investing in retail expansion, marketing, or wholesale partnerships.

“If you want to become a wholesaler or have a café, focus on one thing first: Grow with an accurate profit margin and generate a recurring income,” Donovan says. “Build your wholesale programme to a point where it can be sustainable by itself with a team running it, then branch off and open the café you want. Most people try to do all this at once, and it usually never works.”

Starting roasting operations empowers businesses to make high-quality, freshly roasted coffee more accessible while reducing upfront costs. This not only increases profitability but also creates opportunities to expand into wholesale and diversify revenue streams. By removing the barriers of scale and experience, micro roasters can take control of quality and sustainability from day one.

A passion for coffee quality and traceability is essential to starting a successful micro roastery, but operators also need to take a pragmatic approach.

Roasters need to define their mission and vision, determine the type of business they want to be, and set realistic goals. Picking the right equipment is essential to success, allowing roasters to maintain operations or scale volumes in the future.

Enjoyed this? Then read our article on how the micro roaster market is evolving.

Photo credits: Bellwether Coffee

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There are many ways to buy this equipment. But with an ever-growing number of manufacturers entering the market, it can quickly become overwhelming for businesses – especially roasters with less experience – to find the “right” machines.

To avoid these issues, many roasting businesses decide to buy their equipment from distributors, rather than purchasing straight from the manufacturer. There are several benefits to taking this route, but how do these distribution channels work in the first place?

I spoke to Collin Bay and Bryndon Bay, co-owners of First Crack Coffee, Ben Turiano, owner of Joe Bean Roasters, and Curtis Dunning, owner of Alchemy Coffee Werks, to find out more.

You may also like our article on how different roasters affect coffee flavour.

How do roaster distributors operate?

In addition to buying equipment directly from manufacturers, roasters can also partner with distributors. These businesses essentially act as a bridge between the customer and the manufacturer. They can assist with filling any gaps – which could be language barriers or different time zones, for example – and can also provide constructive feedback to manufacturers.

Collin Bay is a co-owner of First Crack Coffee – a co-roasting facility and equipment distributor which also provides educational courses and consulting services.

“A coffee equipment distributor’s primary purpose is to listen to potential customers so they can learn about their business, identify the roasting system that best suits their goals and needs, and support them over the lifespan of their equipment,” he says. “Distributors need to be well-versed in their market, including understanding emerging trends and different regulations.”

To function effectively, equipment distributors need to build close relationships not just with their customers, but also with machine manufacturers. In doing so, complicated technical issues can be dealt with more efficiently, which can help improve customer loyalty for both distributors and manufacturers.

Moreover, if the two work closely together, distributors can stay ahead of new product releases and regularly update their inventories.

Bryndon Bay is a co-owner of First Crack, which has been distributing roasting equipment in the US since 2013. He explains how distributors operate.

“We order equipment directly from manufacturers and sell straight to roasters and other coffee retailers,” he tells me. “Our sales primarily come through referrals and from current customers who expand their operations and need more or larger-sized machinery.”

He adds that First Crack partners with leading roaster manufacturers like Typhoon, Roaster Dynamics, Buhler, and Proaster to offer a range of machines to customers.

Knowing what roasting equipment to buy

If a roaster chooses to work with a distributor, it’s important to consider which pieces of equipment they need to prioritise. These can include:

• Roasters (including gas, electric, drum, and fluid bed)
• Green coffee silos for storage
• Destoners and graders
• Packaging machinery

The roaster is arguably the most essential of them all. So when partnering with a distributor, business owners need to be aware of all the machines available – including their unique features and quality standards. 

Collin explains how First Crack partnered with Typhoon Roasters.  

“We first encountered Typhoon at a trade show,” he says. “We had never roasted on a Typhoon machine, but when we tasted coffees from roasteries that use them, the quality was undeniable. 

“So we visited Typhoon’s headquarters in Prague, tested the equipment extensively, and asked them a lot of hard questions,” he adds. “We felt that the machines ticked all the boxes for a brand we would like to partner with, so adding it to our roaster offerings was an easy decision.”

Why buy roasters from distributors?

Ultimately, the decision to purchase roasting equipment from distributors or manufacturers largely depends on the customer’s needs. Working with the former in particular, however, can come with a number of benefits.

Distributors can provide roasters with valuable insight on which type of machine would work best for them, as well as any emerging market trends which could influence their choice. What’s more, distributors are likely to answer questions about different machines and equipment more honestly and openly – allowing roasters to make more informed decisions. 

Ben Turiano is the owner and head roaster at Joe Bean Roasters in New York, US. 

“Receiving support is the biggest advantage, especially because most roaster manufacturers are not based in the US,” he tells me. “It’s useful to work with a distributor that partners with multiple brands since every machine will have its strengths and weaknesses.

“Plus, installing new equipment is always a hassle, so being able to ask specific technical questions about installation – and comparing different roasters – is also a bonus,” he adds.

Providing ongoing support after equipment has been purchased is vital. Customers may have questions about configuring software and machine maintenance, or may experience issues with specific parts. Not all of these can be answered or resolved by reading a user manual or searching online, so purchasing equipment from distributors can be particularly helpful. 

Curtis Dunning is the owner and head roaster at Alchemy Coffee Werks in Kansas, US.

“First Crack has always been readily available via phone calls and messages,” he explains. “For instance, I recently had an issue with a temperature probe, and after a phone consultation, I received a new probe with video installation instructions the next day.”

Getting the most out of roaster distributors

Although manufacturers can offer support to roasters, equipment distributors typically provide a wider range of services

“We initially purchased a roaster from First Crack,” Ben says. “When we scaled the business, we purchased a bigger roaster, and since we have scaled again, we are in the process of buying our third roaster. 

“One of the biggest reasons why we chose to work with First Crack is the level of technical support offered,” he adds. “We receive information about machine updates or new roaster brands available. But more importantly, we can easily buy replacement parts, so I can focus my time and energy on roasting while I receive necessary support.”

Educational opportunities

In addition to offering technical support, many roaster distributors also offer educational workshops and training courses, as well as white label services and access to co-roasting spaces.

“Many of our customers take advantage of our free bean-to-brew courses (which include a comprehensive introduction to roasting and cupping) and SCA-accredited programmes,” Bryndon says. “Some also choose to roast their own coffee, while others prefer that we roast on their behalf. 

“Our white-label roasting services tend to appeal to larger-sized clients who have national distribution networks,” he adds.

Roasters of any size, however, can benefit from using a wide range of additional services offered by equipment distributors.

“There is an art to roasting, and First Crack’s courses have helped me to hone my skills and creativity as I build my business,” Curtis says.

When looking to buy a new roaster or other equipment, working with a distributor can be a smart investment. Roasters can benefit from their extensive knowledge of a variety of products, quality customer service, and a number of additional perks – including ongoing support and training. 

At the same time, purchasing machinery from a distributor can help roasters focus more on their businesses – helping them to scale and grow successfully.

Enjoyed this? Then read our article on what coffee roasters learned from the pandemic.

Photo credits: First Crack, Typhoon Roasters

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But one factor that can often be overlooked is the machine itself. While many brands of roasters will perform slightly differently, the type of machine also plays a key role in how heat is dispersed – and therefore how flavour develops.

To learn more, I spoke to Steve Cuevas, head roaster at Black Oak Coffee Roasters and 2023 US Coffee Roasting Championship runner up, and Simo Kristidhi, head of logistics and production at Solberg & Hansen and 2022 World Coffee Roasting Championship runner up. Read on for more of their insight on how different roasters affect coffee flavour.

You may also like our article on how to know when it’s time to upgrade to a new roaster.

Different types of roasters

Coffee roasters around the world use a number of different machines. From more traditional drum roasters to fluid bed machines, they are all designed to roast coffee in different ways. So considering these factors when deciding which type of roaster to buy is important.

Classic drum roasters, for example, are some of the most common machines seen in roasteries, and are usually made from cast iron or steel. Indirectly heated roasters, meanwhile, heat air in a separate chamber and then funnel the heated air into the drum to roast coffee. 

Fluid bed roasters are also a popular option, mostly because the risk of damage to the beans from the heat source is relatively low. By using a stream of hot air to lift and circulate the coffee beans, they aren’t in contact with any hot surfaces in the roaster. 

Finally, recirculation roasters are highly energy efficient because they recycle and reuse exhaust air to heat the drum. However, if too much air is recirculated, it can impart a smokey flavour to the coffee.

How do roasters develop flavours in coffee?

As a result of applying and controlling heat to green coffee, many chemical reactions take place during different phases of the roasting process. These stages include:

• The charge temperature (temperature of the drum or roasting chamber before adding the beans)
• Drying (when green coffee loses moisture)
• The Maillard reaction and first crack
• Development and second crack

The key to developing a desired roast profile – whether light, medium, or dark – is to apply the correct amount of heat at the right times during the entire roasting process. And ultimately, every roaster will have a different approach.

Steve Cuevas works at award-winning Black Oak Coffee Roasters in California, US. He tells me about the method he uses.

“I like to find the fastest first crack I can hit at the capacity I’m roasting with,” he says. “We have to figure out what the largest batch size is for our roaster and in what time frame we can hit first crack.”

For reference, first crack is the sound coffee makes when it reaches a certain external temperature (about 201°C to 207°C, or 395°F to 405°F). This happens because water trapped inside of the coffee is released as steam – causing irreversible changes to the structure of the beans.

“Let’s say we’re roasting 55lb batches, which is 100% capacity for our machine, but we would only reach first crack at about nine minutes with this capacity,” he adds. “For single origins, you would want to hit first crack earlier, so we would make our batch sizes smaller based on the amount of heat produced from the machine.”

Consistent heat application throughout the period when the Maillard reaction (also known as the browning phase, when sugars and proteins transform under heat) will also significantly affect the final flavour profile of a particular coffee.

Does the type of roaster have an impact on flavour development?

One of the main differences between types of roasters is how they apply, recirculate, and retain heat. A cast iron or steel drum roaster, for instance, will retain more heat for longer than a fluid bed or indirectly heated machine. This means that when using the former, you will need to apply less heat in the later stages of the roasting process as most of the initial heat expelled at the beginning stages will be retained throughout the roast. 

To a certain extent, however, the type of roaster you use will not directly impact the flavour of coffee, but different machines do disperse heat in different ways – which any roasting professional must be mindful of.

While a cast iron or steel drum machine won’t necessarily “add” different flavours to coffee than a fluid bed roaster, the way in which both machines apply heat to coffee will impact the overall sensory profile.

Simo Kristidhi works at pioneering Nordic roaster Solberg & Hansen. He has extensive experience using both traditional drum and indirectly heated roasters, and explains to me how he controls airflow differently for both machines.

“If you opt for, let’s say, a filter or espresso roast using a drum roaster then the sweetness and the body will be more pronounced compared to using a roaster with an indirect heat source,” he says. “We tend to roast ‘Nordic’ style, which is usually a lighter profile with more acidity, so the biggest issue for us when roasting with an indirectly heated machine was that the coffees were very clean, but also lacked body.”

Are different types of machines better for certain coffees?

Although there is no one-size-fits-all approach to roasting certain coffees, it’s evident that different types of machines may help to highlight certain flavour characteristics.

Simo tells me that because they result in cleaner flavour profiles, indirect heating roasters work well for higher-scoring coffees that have a lot of sweetness and acidity. On the other hand, these machines can also highlight any defects in the coffee more than other roasters. 

To combat these issues, Simo says he roasts most coffees using indirect heating roasters, and uses a traditional drum roaster for other coffees – particularly those which have more body and sweetness. 

Because of their design, most drum machines produce consistent results when roasting with the same coffee. Any differences between batches are likely to be the result of how roasters apply heat and control airflow.

Fluid bed roasters, however, require a different approach. As these machines apply convective heat more evenly and consistently, they tend to roast coffee more quickly than traditional drum roasters – but sometimes with less precision.

Tips and advice for using different machines

Investing in a new roaster is costly, so it’s unlikely that many roastery owners will own or operate more than one type of machine. But there are some key considerations to keep in mind when using different roasters.

Firstly, gas-powered roasters tend to have more efficient heat transfer and a faster response than electric machines, which can enhance acidity levels. Electric roasters, however, tend to distribute heat more evenly – which can lead to a sweeter and more well-rounded flavour profile. 

When using a drum roaster, it’s essential to consider the drum speed and airflow. A slower drum speed and higher airflow can lead to a more even roast and increased development of more complex flavours. Conversely, a faster drum speed and lower airflow can produce brighter acidity and enhance more fruity flavours.

With fluid bed roasters, it’s essential to take airflow and bean agitation into account. Higher airflow and increased agitation can result in a lighter roast with brighter acidity, while lower airflow and less agitation can lead to a darker roast profile with more chocolatey and nutty flavours. 

Consistency and experimenting

Whichever machine you use, when developing flavour profiles, keeping a consistent roast profile is important. Additionally, recording detailed information about each batch will help you to adjust your roast profile to achieve the desired flavour. 

Finally, experimentation is key. Roasting different coffees to different roast profiles will allow you to discover new and unique flavour profiles.

Whether you use a classic drum roaster or a fluid bed machine, taking the time to understand how your roaster affects coffee flavour development is key.

In turn, you can make much more informed decisions about how and when to control different variables – and achieve the results you want.

Enjoyed this? Then read our article on whether there is a universal way to approach roast profiling.

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At the same time, however, it’s also important for roasters to offer products which suit a range of customers’ needs, including pre-ground coffee. These products are ground and packaged at the roastery, before roasters sell them to consumers.

Given that ground coffee is highly sensitive to a number of environmental conditions, it’s absolutely imperative that roasters seal and package pre-ground coffee as safely and effectively as possible.

To learn more, we spoke with Gian Pietro Balboni, Process Engineer at IMF Roasters. Read on to find out more about packaging and selling ground coffee.

You may also like our article on how roasters can store and transport roasted coffee safely & effectively.

Why should roasters sell pre-ground coffee?

For near enough any specialty coffee roaster, whole bean coffee serves an important purpose. By grinding coffee just before brewing, wholesale customers and consumers alike can guarantee their coffee tastes fresher and better.

However, not all coffee consumers will have access to a grinder – or may not want to invest in one altogether. 

Moreover, a US survey from 2020 found that 76% of people purchased their coffee pre-ground. While this percentage certainly varies from country to country, it’s clear that there is demand for pre-ground coffee.

It’s important to remember that convenience is a major purchasing factor for many consumers. And while price and quality are also key points to consider, some studies have found that nearly half of consumers believe convenience is more important than price when deciding where to shop.

Ultimately, for many consumers, pre-ground coffee is highly convenient. On top of that, there has also been a massive increase in the popularity of pods and capsules, as well as single-serve bags.

At the same time, however, pre-ground coffee products still need to be high-quality to make sure that consumers experience the full range of a coffee’s sensory profile.

Why do roasters need to package ground coffee safely and effectively?

Roasted coffee – whether ground or whole bean – is an unstable product. This is because many chemical reactions take place when roasters apply high temperatures to green coffee. These reactions then create irreversible changes within the cell structure of the coffee beans – and thereby help to develop its flavours and aromas.

During the roasting process, a number of gases – including carbon dioxide (CO2) – form inside coffee beans. Although the roasting process causes some CO2 and water vapour to release, the majority of it remains trapped inside the beans.

Pre-ground coffee, however, is even more unstable than whole bean. This is because when you grind coffee, it releases around 60% to 70% of its CO2 content. This is an indicator of an immediate loss of freshness.

Research has found that the amount of CO2 contained in coffee is a “physical” marker of freshness. Essentially, the more CO2 there is in coffee, the more “fresh” it is.

“Ground coffee also degrades easily when in contact with oxygen because of the oxidation process, which is the main reason for loss of freshness and aroma,” Gian says.

Considering this, it’s important that roasters implement strict protocols and procedures to protect the integrity of ground coffee. If the appropriate controls aren’t put in place, the risk of contamination, as well as the loss of quality and freshness, becomes all too prevalent.

This is mainly because when coffee is ground, the surface area of the coffee beans increases significantly. Essentially, this increases the coffee’s exposure to a number of different variables, including:

• Oxygen
• Heat
• Sunlight

Over a long enough period of time, prolonged exposure to these factors will inevitably lead to a loss of flavour, aroma, and freshness.

Concerns about selling pre-ground coffee

Some specialty coffee roasters may be hesitant about selling pre-ground coffee at all – mainly because the challenges with freshness can be associated with a loss of quality. However, contamination is another challenge to keep in mind.

As ground coffee has a larger surface area – and therefore more exposure to elements and variables – than whole bean coffee, there are more opportunities for contamination. For instance, ground coffee will naturally absorb more moisture, odours, and flavours from its surrounding environment.

Although the roasting process is typically considered a “kill step” (the point where any potentially dangerous pathogens and microorganisms are removed from the product), ground coffee is still susceptible to contamination. This is especially true when it is stored, transported, or packaged improperly.

In light of this, roasters need to ensure that their pre-ground coffee products are stored, transported, and packaged in a way that mitigates exposure to any potential hazards.

What equipment do roasters need?

To sell high-quality pre-ground coffee products, roasters need to ensure they have the right equipment for storage, transportation, and packaging.

“Ground coffee is very sensitive to certain variables, and has a shorter shelf life,” Gian says, therefore packaging needs to elongate shelf life as much as possible. 

Pre-ground coffee products are moved around a lot, ranging from handling by roasters, to transportation, to the consumers themselves.

By the time roasted coffee is ground, packaged, and then sent to the consumer, there is significant potential to lose quality.

To address these issues, roasters need to consider storage systems first.

“IMF’s ground coffee storage systems are designed to preserve freshness and quality,” Gian tells me. “We design specific storage silos which reduce any contact between ground coffee and oxygen in the surrounding environment.”

Nitrogen flushing

As exposure to oxygen is one of the primary factors which reduces the shelf life of ground coffee, some roasters flush the oxygen out of their packaging, replacing it with nitrogen.

“IMF also provides storage systems which allow nitrogen to enter the silo,” Gian explains. “This preserves more aromatic compounds during the degassing phase. 

“The nitrogen-flushing system expels oxygen from the silos,” he adds. “The silos are then under controlled conditions so that there is no contact between ground coffee and oxygen for better aroma preservation.

“Our silos also have high vacuum cycles which forcibly extract CO2 from ground coffee in less time than the typical degassing phase,” he continues.

Roasteries of any size can implement systems like these, but it largely depends on their budgets.

Degassing

“Product freshness and preservation of quality are necessary to assure that residual CO2 in ground coffee is suitable for packaging,” Gian says. This is particularly important, otherwise bags can expand and rupture if the coffee hasn’t been left to degas for a sufficient amount of time.

Considering this, degassing valves can be particularly useful. These are usually contain a cap, an elastic disc, a viscous layer, a polyethylene plate, and a paper filter. As pressure builds up when CO2 gradually releases from coffee, it will eventually pass the surface tension. Following this, the viscous layer will displace the diaphragm, allowing the excess CO2 to escape.

Selling ground coffee is a successful income stream for many roasters, but it’s essential that they know how to store, transport, and package these products as effectively as possible.

Throughout this process, roasters also need a comprehensive plan for preserving freshness (and therefore quality) every step of the way – both before the coffee is roasted and ground, and afterwards.

Enjoyed this? Then read our article on how specialty roasters manage their green coffee supplies.

Photo credits: IMF Roasters

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On top of this, shipping costs for roasters have also increased – squeezing already-slim profit margins more than ever.

Ultimately, it’s important that roasters are able to keep their business costs down to remain profitable. So what are some of the ways they can do this?

To find out, I spoke to three roasting professionals. Read on for more of their insight.

You may also like our article on whether coffee roasters should add robusta to blends if arabica prices increase again.

Why are costs rising?

Over the past two years, hospitality businesses have been facing a number of significant challenges. As a result of Covid-19 lockdown measures in early 2020, many coffee shops and roasters were forced to temporarily close. 

At the time, many business owners were concerned about remaining profitable. According to a UK survey conducted in 2020, nearly 50% of coffee shop owners in the country believed that Covid-19 would significantly affect their revenue until the end of that year.

While there has been some financial recovery following the pandemic, we have seen costs (particularly for food and energy) continue to increase for coffee businesses for several reasons. 

The pandemic has undoubtedly contributed to the ongoing energy crisis as more people than ever before worked and remained at home, meaning demand for energy skyrocketed. 

On top of this, the Russian government’s invasion of Ukraine has worsened the situation – leading to record gas prices and potentially resulting in high energy and food prices for the next three years.

Perpinias Kostas is the owner of Mr. Bean Coffee Company, a roastery in Athens, Greece. 

“In the last few months, roastery operation costs have increased significantly,” he says. “Following the pandemic, the price of shipping containers increased drastically, the price of coffee increased, and the US dollar strengthened against the euro. 

“The energy crisis also increased the cost of packaging materials and fuel for transportation and shipping,” he adds. “This means costs for roasters have skyrocketed, and it’s difficult to not pass these costs onto the consumer, so profits have also been decreasing.”

Furthermore, rising energy and food costs are also impacting consumers. According to research from Deloitte published in October, some 30% of UK consumers are spending less money – up from 21% at the start of 2022. 

Ultimately, this challenging economic climate makes it more important than ever for roasters to keep their costs down.

Breaking down the costs of roasting

Before we can discuss how roasters are able to minimise their costs, we first need to break them down. There are many business costs which roasters need to consider – including equipment, rent, energy bills, shipping and transportation, and more.

Ioannis Papadopoulos is the owner and 3D Mechanical Designer at IP-CC, a roaster manufacturer in Thessaloniki, Greece.

“Purchasing equipment and machinery is often the first – and biggest – upfront cost,” he says. “Roasters, afterburners, and storage silos for both green and roasted beans are essential pieces of equipment in any roastery.”

In order to keep green coffee fresh and free from contamination, it must be stored in cool and dry conditions with as little exposure to oxygen and light as possible. Storage silos help to maintain these conditions, making them essential pieces of equipment for any roaster.

“Moreover, the majority of roasters also need to buy equipment which best suits their needs, so purchasing customised or specialist equipment can significantly increase these costs,” he adds.

Specialist equipment can include custom-branded roasters, machines which have integrated software or smart technology, or more energy-efficient roasters.

Ioannis explains other major business costs which roasters need to account for.

“There are staff wages and the costs of packaging roasted coffee, too,” he says. “You also need to factor in buying green coffee and having a large enough space for roasting and storing coffee.

“It takes around seven to ten days for freshly roasted coffee to degas, which means adequate storage space for roasted coffee is essential,” he adds.

For smaller roasters looking to expand their operations, there are also other business costs which need to be considered. 

“When a smaller roaster expands to become a medium or large-sized coffee business, the costs of training and paying more experienced and skilled staff will increase,” Ioannis explains. 

As a roaster scales its business, the volumes of roasted coffee it sells will also naturally increase – meaning the costs associated with operating machines will as well.

Cost management tips

Considering the numerous costs which roasters need to pay attention to, it can be a daunting task to know where to start reducing spending. 

One of the most significant ways in which roasters can minimise long-term costs is investing in a more efficient and sustainable roaster. 

While older gas-powered machines can roast coffee to a high standard, they can be much less efficient than modern roasters. And with natural gas prices continuing to increase around the world, making the shift towards machines which are less dependent on gas can help roasters minimise their running costs.

“IP-CC understands that investing in new roasting technology and more efficient machines can help roasters to reduce their costs,” Ioannis tells me. “It’s important for roastery owners to understand that adopting new technologies will help them to upgrade and develop their businesses in the long run.”

Having more control over heat dispersion has been an area of focus for specialty roasters for some time now, as it can help them get the best results from their coffee.

One example of an efficient automated roaster is IP-CC’s iRm series machines, which use hot air technology to roast coffee. 

Ioannis tells me the roasters create up to five times the volume of hot air than other commercial machines – as well as up to five times quicker air speed – which he says can help to cut down on a roastery’s costs by up to 50%.

Michalis Katsiavos is the 2018 Hellenic Barista Champion. He also works at Seven Steps Coffee Roasters in Ilion, Greece, where he uses a 5kg-capacity iRm roaster.

“Investing in a more efficient machine is key to helping roasters manage their costs more effectively,” he says. “Roasters that use hot air technology can save between 30% to 40% propane consumption, [which ultimately reduces your costs, too].”

Furthermore, more efficient roasters also tend to be better insulated, which means energy conservation can improve. For instance, IP-CC’s iRm machines are thermally insulated, and also include a smokeless air supply, which can help to reduce costs further.

“In addition to this, this smokeless roasting style can result in more uniform roast profiles, as well as cleaner-tasting coffee,” Michalis explains.

What are the other areas where roasters can reduce spending?

Alongside investing in a more modern and efficient machine, there are other ways in which roasters can minimise costs – such as staffing.

Traditionally, medium and large-sized roasters require a team of staff, which will include a head roaster. This is because production roasting on a large-capacity gas-powered roaster requires a professional overseeing the entire process to make sure consistency is kept high.

However, with the rise of automation and AI-technology in roasting, roasters’ job roles are changing, and they are now winning back more time to focus on other areas of the business. These can include marketing and branding, product development, and improving sustainability practices.

Many newer machines, such as the iRm series, allow roasters to connect specialist software programmes like Cropster and Artisan. In turn, this grants roasters more control over their roast profiles, helping them improve precision and giving them the ability to experiment with more parameters.

Moreover, this grants roasters more time to experiment with their roast profiles, as opposed to repeating them to get the best results.

“Roasting on an iRm allows me to control the temperature in the drum, so that I can enhance the best qualities of the coffee, such as sweetness and juiciness,” Michalis explains.

It’s more important than ever for roasters to keep a close eye on their costs, and profitability is a key question as we enter an environment of economic uncertainty.

While there are many ways for roasters to cut down on costs, investing in a more energy-efficient machine can be a great place to start. Similarly, automating production roasting can give roasters more time to focus on other aspects of the business – such as sales and marketing.

Enjoyed this? Then read our article on why blends are becoming more popular in specialty coffee.

Photo credits: IP-CC

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However, with demand for sustainable coffee continuing to increase, as well as soaring shipping and energy costs, roasters are looking for new ways to appeal to consumers and reduce their spending. One of these includes investing in electric roasters.

So how do electric machines work, and which factors do roasters need to consider when using one? To find out, I spoke to two coffee professionals who work with coffee roaster manufacturer Stronghold. Read on to find out what they had to say. 

You may also like our article on choosing a roaster for your coffee shop.

Exploring different types of coffee roasters

In previous decades, gas was the most commonly used energy source for roasting coffee – no matter which type of roaster was used. Drum and fluid bed roasters are the most common types of machines, with both capable of roasting coffee to a high standard of quality, whether using gas or electricity.

But in recent years, there has been a greater focus on electric machines, which allow roasters to have much more control over different variables.

Amir Navid is the CEO and founder of Kühne Kaffee in Hamburg, Germany – a regional distributor of Stronghold roasters.

“Comparing an electric roaster to a gas roaster is like comparing a Tesla with an old diesel car,” he says. “When roasting using gas-powered machines, roasters often have to make a lot of adjustments to their variables.

“But nowadays, roasters have to spend a lot more time on marketing their businesses,” he adds.

Traditionally, roasters would have to pay close attention to a number of different roast variables, such as temperature and total roast time. However, with the recent rise of electric machines, which often champion automation, roasters are able to spend more time away from their machines and focus on other areas of their business.

“[In some countries], you may also need to own a special licence and a certain type of insurance because of the carbon emissions produced,” Amir says. “Moreover, you also need to account for the additional costs of installing pipes and an afterburner when using a gas-powered roaster.”

Why are more roasters using electric machines?

There are a number of reasons why electric roasters are becoming more popular. One example is the ever-growing demand for more sustainable coffee.

Now more than ever, consumers expect the coffee they buy to be more sustainable. And while a large part of this is centred around more transparency and traceability in the supply chain, sustainability also extends to coffee roasting, too.

Traditional gas-powered roasters can emit several pollutants, such as nitrogen oxide, carbon monoxide, and carbon dioxide. These gases are not only harmful to the environment, but they can have serious effects on human health if inhaled in significant volumes.

Furthermore, these roasters rely on fossil fuels (mainly natural gas) to operate, which are known to contribute to global warming.

As well as this, in recent months, we have seen the price of natural gas rise sharply as a result of the conflict in Ukraine and economic sanctions placed on Russia.

Naturally, this means that the costs of operating a gas-powered roaster have also spiked – tightening many roasters’ margins and forcing them to look for ways to reduce spending.

“Roasters are looking for opportunities to minimise the uncertainty around fluctuating gas prices, as well as the possibility of supply shortages,” Amir explains.

For roasters who use gas-powered machines, the equipment is typically connected to a shared gas supply, which may also be used to heat the workspace, among other things. 

This can also have an impact on the roaster. During colder months, for example, while the central heating is used more frequently, the pressure could drop in the roaster, potentially leading to less consistent roast profiles. 

However, with electric machines, roasters can largely bypass these issues.

Alex Lee is the North America Regional Representative for Stronghold. He explains how electric roasters, such as the automated S9X smart roaster, can work more efficiently and accurately than gas-powered models.

“Rather than manually controlling gas flow, the roaster can manage all of their variables electronically throughout the entire roast,” he says.

Over the past few years, automation and AI have become more widely used in coffee roasting. In essence, these technologies allow roasters to better replicate roast profiles and to improve data analysis and application, thereby also improving coffee quality.

“In theory, a roaster should be able to perform as well as the manufacturer claims it can,” Alex tells me. “However, other variables like the roasting environment, maintenance issues, and even the coffee itself can affect performance.

“When you use gas, no matter how precise the roaster’s electronic control panels are, the energy generation is still too volatile to [have a higher level of control],” he adds. “By using electric automated roasters, we are able to mitigate potential errors as much as possible.”

Understanding how electric roasters work

For roasters to successfully transition from gas to electric roasters, they first must understand how the machines operate differently.

By far the most important factor to consider is the difference in heat transfer. In general, electric machines have more advanced heat transfer systems, which means roasters are better equipped to control a number of variables.

“Stronghold’s S9X electric roaster, for example, has a triple heat management system,” Alex explains. “This includes heat transfer through convection, radiation, and conduction, and the roaster can control all three methods independently of each other.

“This means you can develop roast profiles more purposefully, as well as having the ability to experiment more,” he adds. 

In theory, having more control over different types of heat transfer allows roasters to more precisely control a roast. This can help them get the best out of a given coffee, and maybe even unlock a new flavour profile entirely.

“However, there are a number of factors which can influence how heat transfers from the machine to the coffee, such as the size and density of the beans, as well as varying levels of sugars contained within the beans,” Alex says.

Ultimately, roasters need to account for these differences when developing their roast profiles in order to get the best results from their coffee.

Temperature stability is also important for roasters. The more stable and consistent the temperature inside the machine is, the more consistent the roast profile will be.

“Stronghold’s X-Series roasters include a ceramic band heater around the drum system,” Alex tells me. “Because of this feature, the roaster can actively and purposefully control the temperature inside of the drum, ultimately allowing for more control over heat retention and dissipation.”

Installation is also a factor to consider. With gas-powered machines, roasters need to make sure they have a gas line ready, or get a permit to fit one if they don’t.

However, with electric roasters, installation is significantly more straightforward.

“Of course, with any large piece of equipment, you need to account for the size of the space [to make sure it fits],” Alex says. “But with an electric roaster like the S9X, you don’t need to account for a gas supply – just a stable source of electricity.”

What are the other benefits of using electric roasters?

Besides having more control over heat transfer, electric roasters boast a number of other benefits. This includes a number of cutting-edge features, such as AI-powered technology and other automated systems.

For instance, Stronghold’s S9X X-Lens temperature sensor improves the consistency and accuracy of various different roast profiles by measuring and recording bean temperature, rather than air or drum temperature.

“You can roast a full 8kg batch to maximise your output with no compromise on quality,” Alex explains. “Moreover, Stronghold’s Square platform means you can manage and share roast profiles with different roasters who also use Stronghold machines.

“Because of its user-friendly interface, the S9X can be used by a range of coffee professionals,” he adds. “World Roasting Champions work with our machines, as well as less experienced roasters.”

Amir agrees, saying “The S9X’s AI technology makes it easier to operate, and the precision in making adjustments on this machine are much more accurate than with gas-powered roasters.

“You can achieve quality and consistent results with every batch,” he adds.

Ultimately, with the increasing reliance on technology when using electric machines, roasters are able to diversify and experiment with roast profiles.

“The increased flexibility with different heat transfer combinations allows roasters to be more versatile than ever before,” Alex concludes.

It’s clear to see why more and more roasters are switching to electric machines. Along with natural gas prices and a push to cut carbon emissions, more roasters are also looking to regain control over a range of different variables to get the best from their coffee.

It’s safe to say that in the years to come, we will more than likely see the uptake of electric roasters increase. Just how the technology will continue to develop, however, remains to be seen.

Enjoyed this? Then read our article on how to ensure batch-to-batch consistency when roasting coffee.

Photo credits: Stronghold, Kühne Kaffee

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For coffee roasters, software is mainly aimed at two things: automating parts of the roasting process and giving them more control over a wider range of data points. In essence, this equips them to better optimise workflow, streamline operations, and improve quality control.

But how straightforward is it for roasters to implement new software into their operations, and what are the factors they need to consider when doing so?

To find out, I spoke to two coffee professionals. Read on to learn more about what they had to say.

You may also like our article exploring AI in coffee roasting.

Automation across the board

Over the past few years, it has become increasingly common to use software and data collection systems in roasteries. 

While implementing software can help roasters automate production roasts and spend more time on other areas of their business, data collection allows them to analyse and manage a wider range of variables which they can use to manage their roast profiles. 

However, this hasn’t always been the case. Prior to this shift towards more automation, many roasters had to account for people closely managing each batch.

As far as data is concerned, we now have greater access to a wider range of variables. For example, head roasters have traditionally had to carefully evaluate the characteristics of green coffee to determine the optimal roasting parameters, such as when first crack should occur or how long the total roast time should be.

Throughout the roasting process, roasters also had to keep a close eye on a number of variables themselves. This has historically included changes to bean colour and aroma, temperature fluctuations, and listening for the audible cues of first and second crack.

These are important variables that roasters need to account for when developing roast profiles, so in order to maintain consistency in their roast profiles, they need to collect data. With limited data collection software available, roasters would often keep handwritten notebooks.

However, with automation becoming increasingly prominent, more and more coffee professionals are choosing to implement new technologies and software across their roasteries

What software should you use to manage your roastery?

Today, there are many different types of software available for roasteries, including programmes which monitor and guide roast profiles, as well as those which predict when first crack will occur.

However, deciding which specific piece of software to use will depend on a roaster’s needs. Larger roasters will have different technical requirements than smaller roasters, for instance, and specialty coffee roasters will likely require software more focused on quality control than commercial brands which are more renowned for their output.

Inventory management

Daniel Mendoza is the North American Sales Manager at Cropster, a roasting software company. 

He tells me that inventory management systems are generally the first thing he recommends to roasters.

“Some roasters record all their data on paper, which can mean that their inventories are less organised,” he says. “So one of the first steps towards using more data collection systems for these roasters is inventory software.”

Moreover, many platforms designed to manage coffee roasteries have an inventory management function for tracking green and roasted coffee stock levels. Not only does this help to preserve coffee freshness, it also allows roasters to gain a better understanding of which coffees are more or less popular with customers. 

Daniel explains that most roasting software suites collect a range of data points. These include sample roast profiles, physical analysis of green and roasted beans, and optimal roast profiles, which help roasters remain informed when tracking stock levels or looking for new green coffee.

“When a roaster buys coffee, [the software can store all the relevant data points] for as long as necessary,” he says. “So instead of relying on paperwork or emails, all the information is now stored in one place.”

Time between roasting batches of coffee

Another area where software can benefit roasters is time spent between roasts, or “Between Batch Protocol” (BBP). This refers to all of the actions which take place between the end of a batch and the beginning of a new one.

Before attempting to implement roasting software, Daniel suggests that roasters fully understand each step of their process.

Many roasters follow their own BBP procedures, but it can be difficult for them to know if they are using this time as efficiently as possible.

“A lot of roasters don’t know how their time is spent between batches,” Daniel tells me. “There is no standard protocol in the coffee industry because each roaster defines their own procedure.”

“When roasters record the length of time in BBP, they may find that they are spending five or six minutes between roasts,” he says.

“In my experience, a three minute wait between batches is too long,” he adds. “However, a two minute wait between batches is more ideal because then a roaster only has [a total of] ten minutes of BBP per hour.

“Lorings, for example, are able to have a one-and-a-half minute wait between batches, which means you can do five batches an hour when at full capacity,” he continues.

Managing roast profiles

It’s no understatement that profiling is a key part of any coffee roasting business. As such, software which can support roast profiling and guide production roasts along specific curves are indispensable for many businesses.

A roast curve is a graph which indicates how temperature changes during the roasting process. Many roasters believe the “S-curve” to be a more traditional and straightforward roast curve, which results in a medium roast profile. 

While the S-curve can be a great starting point for less experienced coffee professionals, other roasters may want to develop their own more advanced roast curves. To do so, roasters can analyse a curve and adjust specific variables (such as temperature and airflow) at specific points to slightly tweak the end result.

While this can be done without the use of technology, software can help roasters to design new roast profiles, as well as automating production roasting according to a specific profile. Moreover, software can automatically track the progress of a roast over a set period of time, as well as being able to control the roast variables according to a preset curve. 

However, Daniel emphasises that the type of roaster you use will determine how compatible it is with specific software systems

“We have a customer in Canada who has a second or third-generation roaster,” he says. “They wanted to start using profiling software, but their Probat machine isn’t compatible with Cropster’s programmes.

“They can’t afford a new machine, so they have to focus on using software for inventory and quality purposes without changing the way they roast their coffee,” he adds.

Although it is possible to use roasting software on older equipment, this can be a difficult and risky task. Implementing software on an older roaster can significantly change commonly used roast profiles. For example, it may mean that roast profiles are lighter than usual, which some roasters may not be used to.

Ultimately, these changes could impact a roastery’s branding – potentially turning some loyal clients away – so careful consideration of using software on older equipment is critical.

How can roasting software improve consistency and quality?

For many roasters, adding roasting software to their setup can help them identify any areas of inconsistency – allowing them to improve coffee quality.

John Simonian is the owner of two-time Good Food Awards winner Beanstock Coffee Roasters in Eastham, Massachusetts in the US. He tells me he started using roasting software around three years ago.

“[Before we started using roasting software], we were roasting mostly on a Probat L-12,” he explains. “On this model, the temperature is controlled using a knob on a little metal pole which you pull out and push in to control the flame.

“The pole is marked and divided into ten sections,” he adds. “At different points during the roasting process, you need to move to different sections of the pole. For example, one minute and 26 seconds into the roast, you would need to move the pole to marker number two.”

Reflecting on this process, John says the team were unable to effectively collect and store data which could help them improve their roast profiles. 

“For instance, if the ‘rate of rise’ (RoR) changed, or the exhaust temperature or environmental temperature increased, we wouldn’t know,” he tells me. “When we first implemented roasting software on our machine, we didn’t realise that our central heating line that was next to the gas line for the roasters was affecting our coffee.”

Essentially, roasting software can identify areas which roasters may not notice themselves. John says that by using software, he and his team were able to spot these issues earlier on than beforehand.

How can implementing software affect how you train your staff?

One of the biggest challenges for more established roasters is effectively and efficiently passing on their coffee skills and knowledge to newer team members.

However, thanks to the sheer amount of data points coffee roasters can now have at their fingertips, this process should theoretically be much easier.

Roasters can then develop their training programmes by leaning on their software, and use it as a tool to educate less experienced staff about the process of roasting.

“For me, the increased opportunity for training is a big advantage,” John says. “Roasting software provides us with so much more information that wasn’t available beforehand.

“You can now go back to the cupping table and review roast profiles,” he adds. “You will be able to taste the difference if you make any changes.”

Ultimately, this will not only optimise a roaster’s operations, it will also help to improve overall coffee quality.

Considering the challenges

Despite the clear advantages, roasters can still face challenges when implementing new software.

Introducing staff to new software and data systems could be complicated, as it’s just one of many things that roasters need to consider when it comes to optimising operations and increasing coffee quality.

Moreover, some roastery staff may find it difficult to understand how to operate new software – especially when using more than one new system or platform at a time.

In turn, roasters need to carefully consider which software best suits their needs.

There’s no denying that using more advanced roasting software has its advantages, whether that’s increasing consistency, winning back more time to sell coffee and handle other responsibilities, or giving you the tools to profile new coffees with more precision than ever before.

However, precisely which programmes or software suites might be suitable for a roastery will depend on a number of factors – from your batch capacity and business size to your target audience.

Enjoyed this? Then try our article exploring automation in coffee roasting.

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However, as with any other piece of precise industrial equipment, consistency can degrade over time with regular use. So, what can roasters do to keep their machines consistent? And how should they be maintained? 

To answer these questions and learn more, I spoke to two coffee roasters and a specialist service technician. Read on to find out what they told me.

You might also like our article on using the right ventilation system for your roaster.

Why is consistency important?

For roasters, there is understandably a focus on developing a roast profile for each new coffee they bring in. A “perfect” profile will unlock the flavours hidden within the green beans, allowing the coffee’s best qualities to shine through, whatever they may be.

Once this perfect profile is developed, however, the roaster faces their next challenge: replicating it consistently from batch to batch. 

Luis Fernando Velez is the owner of Amor Perfecto, an award-winning roastery based in Bogota, Colombia. He tells me that it’s incredibly important that roasting technology returns on the investment by producing consistent results for customers. 

“A few weeks ago, a Korean company ordered a huge amount of coffee from us,” Luis says. “They needed 16,000kg of coffee, and we roasted it in five days. We had no issue with the machines [and their consistency].”

Ultimately, having a reliable and consistent roaster allows businesses to respond to these kinds of large orders. It allows them to move quickly, removing any bottlenecks from the process of roasting coffee itself.

Luis also explains that a roaster has an obligation to deliver consistency not just for the customer, but also for the farmers they source from. Roasting coffee to a consistently high degree of quality upholds the producer’s reputation just as it does the roaster’s. 

“[This is why we] put the name of the coffee grower on the bag,” Luis says. “I find it interesting, as in the past, many roasters wouldn’t do that. They were afraid their competitors would go and buy the coffee too.

“However, my philosophy is that if [another roaster] goes to the farmer and buys the coffee, I’ve done my job correctly.”

So, what can go wrong with your roaster?

Over time, regular use of a roaster will naturally cause parts of it to wear down and fail. Machines can also get “clogged”, generally thanks to various buildups that occur during the roast (chaff and coffee oils, for instance). 

Any kind of damage or failure due to continuous use can, over time, affect batch consistency – so keeping your roaster clean and well-maintained is certainly in your best interest.

Joe Thill is a roaster technician at Usonian Systems. He says: “Roasters have what we call ‘wear parts’; expendable components that are generally meant to be fairly interchangeable and can be relatively easily replaced.

“These wear parts prevent wear on other parts of the roaster, which are either more expensive or more difficult to replace – often both.”

However, by understanding which parts of your roaster are designed as “wear parts”, you can target your maintenance, prolong their life, and protect your machine in the long term. This, consequently, will help you to be more consistent. 

“One area where I see lots of buildup is the cooling fan assembly,” Joe says. “All of the ducting attached to the cooling fan is especially prone to a buildup of coffee oil. This condenses on the inside of the duct tubes, and forms a sludge. Over time, this can lead to decreased efficiency in the cooling fan.”

The cooling fan is an essential part of a roaster, as it helps to precisely control and manage temperature during the roast. As the cooling fan becomes less efficient and precise, accurately recreating roast profiles will become more and more difficult.

Joe also notes that how you roast and the profiles you use can actually affect how quickly these buildups occur. With darker roasts, more oil migrates to the surface of the bean as the sugars develop, meaning more escapes into the roaster itself. 

“Roasters that are regularly producing darker roasts for multiple hours a day are definitely going to see an increased buildup of that coffee sludge,” Joe says. “To address it, you can just blow out fan motor housing with a can of compressed air or something. That’s how we clean those fan blades.”

Batch size matters

Another detail to keep in mind for machine maintenance is the batch size of your roaster. As a roasting business grows, it will naturally require larger machines to meet increasing demand. 

A higher batch size can also help increase consistency, however. Roasting two 10kg batches instead of one 20kg allows more room for deviation. 

In a wholesale setting, however, Joe explains that larger roasters are more likely to be used for darker espresso roasts rather than filter roasts (purely because of demand). Consequently, in his experience, this means larger roasters tend to suffer more from these buildups.

“Even though high-capacity roasters have a larger tubing size for their venting to accommodate, we generally see that darker roasts are more frequent and more prevalent in larger roasters,” Joe says. “They also tend to run more often and have higher workloads, [causing more of a buildup].”

Ultimately, while investing in larger capacity roasters helps to make your roasts more consistent, it also makes regular maintenance even more important.

How can roasters keep their equipment consistent?

Some parts of a roaster will naturally wear down over time with regular use. David Fullerton is the owner of Acoustic Java, a roastery based in Worcester, Massachusetts. He tells me that he uses a Loring S35 Kestrel, but notes that there are specific components he keeps an eye on in particular.

“So far, it’s just the non-steel parts,” he says. “Components such as the edges of the cooling bin paddle fins and the hose connecting the rolling loader bin cart to the roaster hopper.”

He says that a regular maintenance schedule can help you maintain these components – the “wear parts”, as Joe calls them.

David says: “There are some daily maintenance tasks [you can take on], such as emptying the chaff barrel. After that, of course, there are weekly, monthly, and annual tasks, from cleaning the cyclone spray nozzle to checking the exhaust stacks and cleaning as needed.” 

However, roasters should be wary that depending on the age of their roaster, a different approach to keeping things consistent should be taken. For instance, modern Loring roasters rely on airflow to roast the beans, as opposed to classic gas drum roasters. This means they require a different approach to maintenance.

Joe says that ensuring consistency with a Loring starts with making sure airflow control is as precise as it can be. “The key is blowing out the fan motor housing with compressed air (or something similar). A lot of the time, that can dramatically increase efficiency in all of your fans. 

“In a Loring roaster, you have a couple of different motors controlling a couple of different fans throughout the roaster. Making sure those parts run at peak efficiency is important for longevity… it’s the most important part of the roaster, and the most expensive component to replace.”

Other steps

However, a regular in-house maintenance routine alone may not help you maximise roster consistency. There will naturally be times throughout your roaster’s life cycle where something extra is needed.

For instance, Joe tells me that Usonian offers yearly and bi-yearly service programmes to ensure their customers’ machines are always functioning at the optimum level. They offer a technical service package with an on-site visit from a skilled, experienced technician.

Joe says: “This includes identifying a few different parameters and taking measurements, things along those lines. We have a basic standardised checklist of things to go through, such as paddle measurements within the drum.”

Taking these measurements allows the service professional to monitor any wear or degradation over time, comparing it to figures from previous years to understand how the machine is changing.

However, it’s not just a mechanical or technical service that you should focus on. David also notes that software upgrades can help your machine stay consistent from batch to batch, too.

“Usonian recently upgraded our machine with ‘turbo burner’ software. They facilitated the entire process with us, in collaboration with Loring.

“Thanks to careful planning, we experienced no downtime, and our few follow-up operational questions were addressed by the technician as they arose following the successful installation.” 

Finally, having a specialist on-hand for any more immediate issues can help maintain consistency if your roaster suddenly encounters dramatic difficulties. For instance, Luis tells me that remote support from Usonian helped with a major order. 

“​​Before [started on a contract that required us to roast] 1,000kg over five days, [our larger roaster stopped working at 100% power]. We called Usonian, and received [everything we needed remotely] to recalibrate the burner. That was it.

“All it took was a couple of hours on the morning before we started roasting, and we were ready.”

Batch consistency should be a key priority for any specialty coffee roaster, but maintaining it over time is easier said than done. However, the more you understand about the inner workings of your machine, the better equipped you will be to understand why consistency changes, and what you can do to help.

Ultimately, creating daily, weekly, and monthly maintenance schedules will be key. However, in the long term, partnering with a technical specialist and making sure your machine is regularly serviced is invaluable. 

Enjoyed this? Then you’ll like this article on upgrading your coffee roasting space.

Photo credits: Usonian Systems

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The fluid bed roaster has technically been around since the 1970s, but has become more popular in recent years. It heats the beans in a fundamentally different way, leading to some key differences in the roast.

To learn more, I spoke with a roaster and two manufacturers. Read on to find out what they told me. 

You might also like our guide to airflow in roasting and how you can control it.

A history & guide to fluid bed roasters

The technology for fluid bed roasters has been around since the early 1970s. In the 1960s, chemical engineer Michael Sivetz realised after working in a polyurethane plant that he could adapt a process used for drying magnesium pellets to roast coffee, thus inventing fluid bed roasting.

For years, fluid bed roasters were consequently referred to as “Sivetz roasters”. And while they attracted a small following in the 1970s, they didn’t really become popular until much later.

The difference between drum and fluid bed roasting is simple. In a drum roaster, the metal drum is heated, which then transfers heat to the beans. However, with a fluid bed roaster, the air is heated first and then blown through the roaster bed, eliminating the need for a heated drum.

Tim Monson is the Head Roaster & CEO at The Monsoon Roastery in Springfield, Massachusetts. He says: “Fluid bed roasting uses convection heat, rather than conduction or induction. 

“In a typical drum roaster, whether it is electric or gas, you have a rotating drum with heat coming from underneath it; sometimes it’s direct, sometimes indirect,” he continues. “In a fluid bed roaster, you’re creating your heat and your airflow from the bottom. 

“This keeps the beans in a constant rotation, so that they’re not actually roasting on a surface; they’re being roasted from the air and the pressure moving in the chamber.” 

As the hot air flows through the roaster, the force lifts the beans into the air, causing them to float. This effectively means the coffee beans are resting on a “bed” of heated air, which is where fluid bed roasting gets its name from.

Ken Lathrop is the owner of Coffee Crafters, based in Post Falls, Idaho. He notes that after the beans are roasted on this bed of heated air, they still need to be cooled externally, even though it might look like this can take place inside the machine.

“We tried to do that in the beginning, and it didn’t work,” he explains. “If you do a good job of insulating your heat chamber, it holds the energy in, so when you shut it off, it’s still roasting.  

“What we do is we release the beans into a separate chamber and then flash cool them. A ten-pound load will cool in about 90 seconds,” Ken tells me. “We direct a lot of air into the bean cooler to suck the heat out of the beans as quickly as possible.”

Gökhan Mithat Karakundakoglu is an Export Manager and SCA Authorised Trainer at Toper, a Turkish roaster manufacturer. He says that Toper has been producing roasters since 1954, but has only recently started producing fluid bed roasters.

“There has been a growth in demand from customers who wanted to start a more boutique style of coffee company,” Gökhan says. “They [often] feel that the appearance of the machine is more stylish than a classic drum roaster.

“Our fluid bed roasters only run on electrical power, which is useful for roasters who don’t have a direct gas supply.” 

What are the key differences in flavour when roasting on fluid bed and drum roasters?

For starters, Tim says that certain origins and processing methods can really shine on a fluid bed roaster.

“I find that a lot of naturally processed coffees tend to really pop with the direct convection,” he explains. “They seem a little bit cleaner, and it helps propel some of the sweetness.”

However, Gökhan notes that testing Toper’s fluid bed models led to both positive and negative feedback. “We have found that some fluid bed roasting results end up a little dry compared to a drum roaster,“ he tells me. 

With drum roasters, roastmasters monitor the amount of air entering and leaving the roaster to maintain a certain moisture level for specialty coffee. If coffee is roasted beyond a certain moisture level, becoming “dry”, it will lose complexity and its more subtle flavours.

However, because fluid bed roasters only use air to heat the coffee, rather than residual heat from the drum, moisture loss is more of a concern.

If too much moisture is lost early in the roast, the beans can end up being flat tasting once roasted.

However, Gökhan also notes: “Because you are only using hot air to roast the beans, [it is easier] to prevent tipping (also known as scorching), which can happen easily in a drum roaster with certain beans.”

Tim also says that while roasters might assume roast curves and profiles are fundamentally different on drum and fluid bed roasters, they are actually deceptively similar. 

“Fluid bed roast curves are within similar parameters for classic roast curves,” he notes. “However, it depends on the bean; the convection means factors like how high it was grown and the processing [play a part].

“Because you’re throwing heat directly onto the bean, you need to be a little bit more gentle with your rate of rise to avoid scorching.”

Ken adds that fluid bed roasters can be used for both light and dark roasts, but notes that they’re excellent for more developed profiles. “One of our customers would tell you is that he likes dark roasts better out of a fluid bed roaster because you can take it to a darker roast profile and cool it more quickly. 

“At some point when you’re roasting, you’ll hit that breakpoint where you start drying the oils and sugar down in the beans with a drum roaster. Fluid roasters are really good at doing a dark roast.”

Energy consumption: Fluid bed vs drum

Understandably, energy efficiency is a key priority in today’s coffee sector. Consumers are increasingly looking for more responsible and sustainable products. In addition, technology with a lower carbon footprint and less energy use will be cheaper for a roaster to maintain. So, are fluid bed roasters more energy efficient?

The answer is that it depends on the machine. Ken says that at Coffee Crafters, energy efficiency is a key focus for the roasters they manufacture. However, historically, this has not been the case. 

“The original Michael Sivetz design required a huge 350,000 BTUs of heat and a massive amount of air,” he says. “However, we’ve done extensive research in the last seven years. We’ve started raising the air pressure in the heating chamber, allowing us to [roast] larger loads with a lower amount of air. 

“Our new 25lb roasters are probably going to end up needing less than 100,000 BTUs of heat,” he adds. “We’re trying to achieve about 3,500 BTUs per pound of green coffee, which would actually be more efficient than a gas roaster.”

Tim also notes that much like drum roasters, fluid bed roasters can be fully electric, and says that he has the option to choose where his electricity comes from.

“I source my electricity entirely from renewable energy sources,” he tells me. “This means that we’re not burning fossil fuels and that the energy we’re getting comes from a combination of wind and solar.”

As well as helping reduce the company’s carbon footprint, this may also make it more attractive for consumers who exercise greater environmental awareness in their buying habits.

What are the advantages?

For many, the advantages of a fluid bed roaster over a conventional drum roaster come down to two main factors: cost and ease of use. These are particularly important for roasters at the beginning of their journey.

Tim tells me that he started his journey at Monsoon on multiple small-batch home machines. He says that fluid bed roasters were more affordable, and helped him to scale up and roast larger batches while still maintaining quality.

“I actually went with the fluid bed roaster as a little bit more of an economic point,” Tim explains. “I found myself having to relearn a little bit of what I was doing, but it was actually closer to what I started roasting with, the popcorn popper right at the beginning.”

Ken adds that the ease of use is a key point for most Coffee Crafters customers. “One of the advantages is in the simplicity,” Ken explains. “Some 75% of our customers have little to no roasting experience when they start their business.”

Given that fluid bed and drum roasters also offer the same markers for development throughout the roast – and that traditional curves and profiles are at least somewhat similar – it can also be easy for more experienced roasters to make the switch.

Ken also adds that the simplicity isn’t just in the roasting, explaining that it’s “simplicity in operation and simplicity in maintenance”. Fluid bed roasters are often designed in a much more accessible way, making them easier to repair if something does go wrong.

“Our roasters only have one moving part, which is the loft motor that locks the beans,” Ken says. “Everything else is solid-state electric, meaning [the parts are] really durable, easy to work on, and easy to install. We designed them to be installed in home roasting environments, and certified them for food safety and coffee shops, but people can install these in their garage or their basement.”

While fluid bed roasters are by no means everyone’s first choice and perhaps less viable in a commercial setting where volume is the main priority, they certainly have their place in coffee roasting and are becoming more popular. 

There’s no doubt that drum roasters will remain mainstream, but fluid bed roasters can be an excellent and often more economically viable option for roasters who want something more affordable and compact. However, whether or not they will become more popular in the years to come remains to be seen.

Enjoyed this? Then try our article on defining your roast profile.

Photo credits: Coffee Crafters, The Monsoon Roastery

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