Facilities
Gloria Jean's Roasting Facilities
Gloria Jean's Coffees has recently completed the installation of their state of the art roasting and manufacturing facilities.
After receiving and viewing several submissions of roasting equipment, Gloria Jean's Coffees decided on the highly regarded and respected Brambati roasting equipment together with a fully integrated andautomated green coffee handling system.
This would be the most sophisticated equipment ever to be used in Australia. The entire system is fully automated and completely integrated.
- The process starts with the opening of the green coffee bags- the system automatically opens green coffee sacks and disposes
of the open bags into an empty bag holder and conveying green
coffee into the green coffee de-stoner.
- Green coffee de-stoner - is highly sophisticated and able to
analyse and separate any foreign material that could have passed
through at the time of bagging the green coffee on the farm.
- Green coffee grading machinery - once the coffee has passed
through the de-stoner it is graded to separate smaller beans from
stock enabling all the beans to be of same size and proportion
prior to roasting.
- Automatic air blowers - the green coffee is now transported
by automatic air blowers into green silos, each holding 5 tonnes
of green coffee. Gloria Jean's Coffees has 10 such silos.
- Central control room - the entire operation is conducted from
a central control room and is fully computerised.
Green bean silos to the roaster
The two Brambati fully automatic integrated roasters are state of the art with their individual computers and printers, capturing the entire roasting profile per batch of coffee roasted and these are modem linked to Italy who can also preview the correct use of these roasters.
The roasters are fired by natural gas through a Weishaupt burner, which are once again, the best on the market. Once the green beans have reached their desired colour, roast profile, and their optimum to produce the best aromas, flavours and body, and also the desired Agtron reading, the roast is then water quenched in the drum, prior to dropping it on a cooling tray.
The quench allows the beans to cool rapidly and preserve their inherent quality.
Cooling to de-stoning
Once the beans have cooled, they are passed through another de-stoner and a series of magnets, once again to ensure that all foreign material is totally separated prior to going into the holding silos.
Roasted coffee silos
The roasted coffee silos receive the just concluded roasted beans and these are weighed prior to entry into the silo giving an accurate roasting loss in the process of roasting.
We have 10 silos, each with the capacity of 5 tones.
Blending drum
The roasted coffee beans are then passed through the blending drum where there is a further process of sifting any chips and broken beans allowing only whole roasted beans to be transported to the fully automatic form fill and seal machine - Dolzan.
We have 4 Dolzan machines, one for straight roasted coffee beans, another for flavoured and flavoured ground coffee beans, one for straight ground coffee beans and the last one for cocoa and other free flowing products.
Form fill and seal machine
The Dolzan form fill and seal machine is once again the state of the art with its own printer, date coder, batch code, together with valve applicator, provision for purging the bag prior to sealing with nitrogen to eliminate any air that is trapped within the bag. These machines are also fitted with metal detectors and have been adapted and have a separate unit, which can be hooked onto the main machine to produce vacuum-packed bricks of coffees. The capacity of this machine is to pack between 50g to 1kg brick packs of coffee.
Form fill and seal machine to check weigher
Once the bags have been filled in the form fill and seal machine, they are then passed through a check weigher, which checks the accuracy in weight overs and unders of the coffee prior to being packed into the carton which is then date product coded, and also batch coded.
Flavoured coffees
Flavouring is carried out at the point of having concluded the roasting cycle and prior to entering into the silos from where it is transported into a flavouring drum, which is sprayed with the desired flavour with the pre-determined quantity, and the drum is tumbled for 10 - 15 minutes prior to the flavouring process is duly completed. This coffee then proceeds to being filled through the Dolzan form fill and seal machine conducted in the flavouring room.
Bartelt sachet machine
We also have a Bartelt for seal sachet machine, which is capable of packing any free flowing product from 10g through to 250g bags. This is predominantly used for coffee filter bags and cocoa sachets.