The Flavourtech Integrated Extraction System (IES) has emerged as a transformative technology in the production of ready-to-drink (RTD) coffee and tea, as well as premium liquid coffee and tea concentrates. With a growing global appetite for high-quality, flavourful, and health-conscious beverages, the IES provides a solution that aligns perfectly with the evolving preferences of Gen Z and Millennial consumers.
The global surge in RTD coffee and tea consumption
The demand for RTD coffee and tea products is experiencing unprecedented growth worldwide. According to industry reports, the global RTD coffee market alone is projected to reach a valuation of over $167bn by 2030, growing at a compound annual growth rate (CAGR) of 6.2%.[i] The surge in demand is being fuelled by a shift in preferences, driven primarily by Gen Z and Millennial consumers. These younger demographics prioritise convenience, sustainability, and health benefits, making RTD beverages a perfect match for their busy lifestyles.
“Tea and coffee have long been cultural staples, but current trends lean heavily toward premiumisation and innovation,” says Tim Birks, Flavourtech’s European Sales Manager. “Consumers are no longer satisfied with standard offerings. They seek products that deliver exceptional flavour profiles, natural ingredients, and minimal processing to maintain the raw material’s natural health benefits. RTD coffee and tea fulfill this demand, offering beverages that are not only convenient but also rich in flavour and health benefits.”
Flavourtech’s Integrated Extraction System: A technological revolution
Birks has been at the forefront of the RTD coffee and tea market developments for close to 20 years. He has seen the evolution of consumer tastes and preferences, as well as processing technologies.
“Not all RTDs are the same; take for example, RTD coffee. Many are simply bland instant coffee dissolved in water or with milk. Flavourtech’s IES for RTD is a solution designed to meet today’s demand for premium RTD products. It combines several innovative processes into one seamless system, ensuring the production of beverages with superior flavour, aroma, and quality.”
The Integrated Extraction System: capturing the essence of flavour
At the heart of the IES is the Flavour Extraction Module; a key component that sets this system apart from traditional extraction methods. Birks continues, “This module comprises Flavourtech’s Spinning Cone Column (SCC) technology and is designed to capture the desirable top notes of roast coffee beans or tea leaves at the very start of processing when they are freshest and best. These top notes are the volatile compounds responsible for the fresh and distinct aromas that today’s consumers associate with high-quality beverages.”
The IES works by creating a slurry of ground coffee or tea leaves mixed with water. This slurry is then subjected to precise conditions that ensure the delicate and desirable flavour compounds are captured intact. Unlike conventional methods, that lose these top notes during extraction, the IES ensures they are preserved, resulting in a final product that is both aromatic and flavourful.
The system’s unique process is outlined below:
- Roasted coffee beans or tea leaves are milled under a blanket of cold water through the Slurry Preparation Module. The water acts as a carrier for these volatile aroma components which are subsequently captured in the Flavour Extraction Module.
- Brewing or extraction temperatures of 100oC occur in the SCC, for only 30 seconds. With other techniques, this could take many minutes or even hours. The slurry, consisting of the beans, or leaves, and water, passes from the top to the bottom of the column in 30 seconds. Steam is used to brew the coffee or tea gently as well as strip out the natural aroma from the slurry. These natural and desirable R&G coffee and tea notes are then condensed and stored in a chilled vessel for later use.
- The de-aromatised slurry then enters the Clarification Module to separate the coffee beans or tea leaves from the extract. This extract can then be used for RTD products with the captured natural flavours added back to produce a full-flavoured beverage or can be concentrated with Flavourtech’s Centritherm® evaporator to produce a coffee or tea concentrate. This unique thin-film evaporator has a 1 second heat contact time and low evaporation temperatures of 50°C avoiding damage to flavour, colour and bioactives. The resulting coffee or tea concentrate can also be mixed with the aroma and spray or freeze dried to produce a soluble powder with the highest level of R&G coffee or tea flavours. Such high-quality instant coffee is now as equally popular for use in cold beverages as it is in hot drinks, especially with younger consumers and in countries with hotter climates.
- The flexibility of the IES means the same plant is also able to process cold-brew coffee or tea (at lower process temperatures) in a continuous system that is quick, automated, and consistent.
- Cold brew manufacturers can also benefit from Flavourtech’s new partnership with Danish company, Aquaporin A/S. Aquaporin’s Forward Osmosis (FO) systems allow the concentration of cold brew extracts without heat, so maintaining the integrity of their delicate flavour profiles. Aquaporin systems employ Aquaporin proteins which have evolved over millions of years in nature to efficiently transport water molecules while excluding other substances, making them an ideal solution for concentration of cold brew coffee or tea.
Innovation to shape the future
As the RTD market continues to grow, innovation will remain a critical driver.
“Flavourtech’s IES represents a significant leap forward in beverage processing technology, enabling manufacturers to stay ahead of trends and deliver products that exceed consumer expectations,” says Birks. “By investing in advanced systems, like the IES, companies can not only enhance the quality of their offerings but also strengthen their position in a competitive marketplace.”
For more information, download our brochure on the Integrated Extraction System.
[i] https://www.grandviewresearch.com/industry-analysis/ready-to-drink-tea-and-ready-to-drink-coffee-market
