Processing Methods: Where Fruit Becomes Flavor

Once harvested, coffee must be processed to remove the outer fruit layers and reveal the bean inside. But how that fruit is removed, and how the bean is treated during each stage, affects everything from body and sweetness to clarity and acidity. The steps involved vary by method, and each method creates a distinct flavor signature. Here’s how the core processing styles differ.

Natural (Dry) Processing

The natural process is the oldest method and is still widely used in drier climates. Here, the entire cherry, fruit, skin, and all, is left intact.

• Sorting: Cherries are hand-sorted to remove unripe or damaged fruit.
  
  
• Drying: Whole cherries are spread out under the sun on raised beds or patios. They’re turned regularly to ensure even drying and prevent mold.
  
  
• Fermentation: As the cherry dries, a natural fermentation takes place inside the skin, imparting a deep, jammy character to the bean.
  
  
• De-pulping: Once fully dried, the husk is removed mechanically to reveal the green bean inside.

This method creates complex, fruit-forward cups with a heavy body. It’s used in Ethiopia, Uganda, and Brazil for boldest blends.

Washed (Wet) Processing

In washed processing, the goal is to remove all fruit residue from the bean before drying. This emphasizes clarity and highlights the original character.

• Sorting: Cherries are sorted by size and density in water tanks. Floating, under-ripe cherries are discarded.
  
  
• De-pulping: Machines remove the outer skin, exposing the sticky mucilage-coated beans.
  
  
• Washing & Fermentation: Beans are fermented in water tanks for 12–48 hours to break down mucilage. They’re then thoroughly washed.
  
  
• Drying: Clean beans are laid out on patios or raised beds until they reach optimal moisture levels.

Washed coffees from Kenya, Colombia, and Rwanda deliver crisp acidity, floral aromas, and exceptional balance.

Honey (Semi-Washed) Processing

A hybrid of the natural and washed processes, honey processing keeps part of the fruit’s mucilage intact during drying. The name “honey” refers to the sticky texture, not the flavor.

• Sorting: Cherries are selected by hand or flotation.
  
  
• De-pulping: The outer skin is removed, but varying levels of mucilage are left on.
  
  
• Drying: Beans are dried with mucilage still attached, often under shade or with careful monitoring.
  
  
• Fermentation: Minimal or no fermentation occurs; instead, the flavor is influenced by how much mucilage remains.
  
  
• Hulling: Once dried, the remaining parchment and fruit layers are mechanically removed.

This method yields sweet, medium-bodied coffees with soft fruit notes.

Wet-Hulling (Giling Basah)

This Indonesian-specific method creates earthy, full-bodied coffee with low acidity.

• Sorting: Cherries are sorted manually.
  
  
• De-pulping: Freshly harvested cherries are pulped shortly after picking.
  
  
• Fermentation: Beans are fermented briefly to loosen mucilage.
  
  
• Hulling: While beans are still wet (about 30–40% moisture), the parchment is removed, a step unique to this method.
  
  
• Drying: Beans are then sun-dried to reach exportable moisture levels.

Wet-hulled coffees from Sumatra and Sulawesi are known for their rustic, deep, and sometimes savory character, perfect for drinkers who crave boldness.

Each method involves multiple, deliberate stages that must be adapted to the local environment. At TZB, we don’t just care about the process used; we study how well it was carried out. Because that’s where true flavor lives.

Grading, Green Beans, and Defects: Behind the Scenes of Quality

Once processing is complete, the beans are milled, sorted, and graded. Before roasting, coffee is known as “green coffee,” raw, dense, and full of potential.

The grading process involves:

• Size sorting: Larger beans tend to be more desirable and roast more evenly
  
  
• Defect sorting: Beans are checked for quakers (underdeveloped), insect damage, mold, and physical flaws
  
  
• Moisture level: Ideally 10–12% to ensure safe storage and even roasting

Grade 1 and 2 coffees are the highest levels based on global standards. These undergo cupping, a sensory evaluation where our tasters assess aroma, body, acidity, sweetness, and balance. If a bean passes this test, it continues the journey. If not, it doesn’t cut.

Instant vs Ground Coffee: What Sets Them Apart?

Though they may look similar in your cup, ground and instant coffee have wildly different journeys.

Ground coffee is the product of freshly roasted beans that are ground to a specific consistency for brewing. The flavor, aroma, and oils remain intact because the coffee hasn’t been brewed yet. You brew it fresh, extracting all the volatile compounds at home.

Instant coffee, on the other hand, is brewed in industrial machines and then dried into powder or granules for convenience. It dissolves instantly in hot water because it has already been brewed.

While ground coffee delivers maximum complexity and freshness, instant coffee trades nuance for speed and shelf stability. That said, not all instant coffee is created equal; the method of drying greatly affects quality.

How Instant Coffee is Made: A Closer Look at the Process

Instant coffee may be all about speed and convenience, but the behind-the-scenes process is anything but rushed. Manufacturing instant coffee involves careful control of temperature, extraction, and drying to retain as much of the bean’s essence as possible.

Step 1: Roasting and Grinding

Just like conventional coffee, the process starts with green beans that are roasted to the desired profile. For instant coffee, the roast is typically on the darker side to ensure the intensity of flavor. Once roasted, the beans are ground very finely to maximize extraction.

Step 2: Brewing the Coffee Extract

The ground coffee is then brewed in large industrial equipment under high pressure. This brewing process concentrates flavor in a way that mirrors a very strong batch brew. The result is a thick, dark coffee extract that contains the core soluble compounds found in any high-quality cup.

Step 3: Concentration and Filtering

This brewed extract is then filtered to remove insoluble solids and is sometimes concentrated further using evaporation methods. This improves efficiency in the drying phase and reduces the risk of flavor degradation.

Step 4: Drying into Powder or Granules

Now comes the drying, the most defining step of instant coffee production. There are three main methods, each with pros and trade-offs:

Spray Drying
In this high-speed method, the coffee extract is sprayed into a tower of hot air (usually around 180°C). As it falls, the liquid evaporates, and dry particles settle into a fine powder. This is the most economical and common method, but the heat can dull some of the delicate flavor notes.

Agglomeration
This is a refinement of spray drying. The powder is rehydrated slightly and treated with steam to form larger, more uniform granules. These dissolve faster in water and offer a better mouthfeel, though they still lack the depth of brewed coffee.

Freeze Drying
The highest-quality method. The coffee extract is frozen into slabs at -40°C, and then broken into small pieces. These frozen chunks go through a sublimation process where ice is removed in a vacuum chamber. The result? Beautiful crystal-like granules that preserve complex aromas and flavors far better than the other methods.

How Ground Coffee is Produced: The Final Frontier Before Brewing

Once beans are roasted to perfection, they enter their final transformation: grinding.

Grinding is more than a mechanical step; it’s a make-or-break moment. A fine grind extracts faster (ideal for espresso), while a coarse grind suits slower brewing methods like the French press. At TZB, we match grind sizes to brewing recommendations and use calibrated grinders to ensure consistency.

We also carefully control degassing (resting freshly roasted beans to allow carbon dioxide to escape) and then pack each grind in nitrogen-flushed, air-tight packaging to lock in freshness.