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DRUM SEASONING PROCEDURE
PLEASE READ AND FULLY UNDERSTAND THIS PROCEDURE PRIOR TO
STARTING THE SEASONING PROCESS
The drum of the roaster must be seasoned before roasted coffee is fit
for consumption. Use an inexpensive coffee for the seasoning process.
Do not use a Robusta coffee as it does not emit as much oil for
seasoning the drum. The new drum requires from 8 to 12 seasoning
roasts to become properly oiled. Each seasoning roast requires about
50% of roaster capacity (IR 1 / 2.5 USE FULL BATCH) of coffee,
enough to fully cover the drum's lower surfaces. During seasoning, the
roaster should be operated for 30 – 60 minutes with the oily beans
tumbling in the drum at a temperature of 425°F – 460°F or until the
beans become dry. After completion of each seasoning roast, discard
the roasted coffee after it cools. It may take additional roasts to achieve
the best flavor from your new roaster. Seasoning the roasting drum will
also give you the opportunity to become familiar with the roaster's
controls and the roasting process.
1. Preheat the roaster to ~ 420ºF.
2. Fill hopper with the pre-described amount of beans.
3. Move the air control lever to the "THROUGH COOLING BIN"
position.
4. Activate the hopper gate handle to load the green beans from the
hopper into the drum to start the roasting/seasoning process
5. Set the gas output to approximately 50%.
The coffee will change in color from green to a pale yellow (4-6
minutes).
During this progression look through the drum door view window, you
will start to see chaff, the bean's outer skin, separating from the coffee
bean. Unwashed coffee has considerably more chaff than washed
coffees and decaf coffees have almost no chaff. The bean
development and color can be observed by using the sample trier.
6. When the coffee reaches the yellow stage ~280°F, move the air
control handle to the "50/50" (middle) position. This allows for a
more uniform heat.
As the coffee reaches the yellow stage, the moisture in the coffee that
was a good conductor of heat early on in the roast, is now turning to
steam. At this stage in the roast, the air flowing through the roasting
drum becomes a more uniform heat medium
MANUAL IR-5/IR-12 ROASTER
QUICK START GUIDE
ATTENTION!!
ALL SYSTEMS (Electrical, Gas, and HVAC) MUST BE
CONNECTED, FUNCTIONING AND INSPECTED (if required) PRIOR
TO USING THIS QUICK START GUIDE
As the coffee reaches a temperature of 340°F (171°C) the chemical
changes in the coffee start an exothermic reaction (the chemistry creates
its own heat). This exothermic reaction continues through the remainder
of the roast and therefore the gas % should be reduced during this
period until the end of roast.
7. When the coffee approaches ~385°F "1st crack", reduce fuel % and
let the roast progress in the full roasting stage until the coffee develops
through the second crack (~435°F) and oil begins to appear at the tips
of the beans (try and reach ~460°F slowly).
8. When you begin to notice the first traces of oil, turn the gas control
"OFF." Note: Due to the exothermic reaction (the chemistry creates its
own heat), the bean temperature can continue to rise on its own with
gas turned off.
W A R N I N G
Pay close attention to the temperature at this point.
THE TEMPERATURE RISE ABOVE 480°F!!
with a High Temperature Limit System that shuts the gas off at 485°F.
However, the temperature can continue to rise due to the exothermic
reaction of the bean. If the coffee is not removed from the drum
before 500°F, the coffee may ignite. Have a water source or CO2
fire extinguisher nearby.
High Temperature Limit Module Explanation
At 475°F, the main burner shuts off, but the pilot does NOT shut
off (No alarm sounds). At 485°F, the alarm will sound and the
High Temperature limit shuts down the roaster's entire gas
system. (If this happens, wait for temperature to reduce and reset
the roaster)
9. Let the coffee roast in its own liberated heat until the beans are fully
oiled and almost black. Leave the coffee turning in the drum for 30 – 60
minutes or until the beans are dry to help fully coat (season) the drum.
10. Once the beans become less oily, turn on the "AGITATOR" and
move the air lever control to the "THROUGH COOLING BIN"
position and discharge the coffee into the Cooling Bin.
Repeat seasoning cycle if scorching or tipping occurs during normal
roasting.
Keep this guide with the roaster at all times
Preheat the empty drum until the Bean temp display (1)
1.
reads 415º F or until you reach your desired charge
temperature.
Load the green beans into the hopper funnel after the
2.
roaster's empty drum has been preheated.
Prior to starting the roasting process, move the airflow control
3.
lever to the "Through Cooling Bin" position.
Move the hopper gate lever up to release the green beans
4.
from the hopper into the drum.
Move the lever down to close the hopper gate.
5.
Adjust the flame control to an appropriate heat setting
6.
batch size.
When the beans appear yellow in color (~270°F), move the
7.
air flow control lever to the "50/50" (mid) position.
When the beans approach "1
8.
air control lever to the "Through Roasting Drum"
DO NOT LET
The roaster is equipped
position.
Reduce gas setting and approach the desired finish
9.
temperature
10.
In preparation for discharge of the roasted beans, move the
air flow control lever to the "Through Cooling Bin"
position.
Turn on the "Agitator" (8)
11.
Switch the flame "Pilot Only" (3)
12.
13.
Using the Sample Trier, sample the beans frequently.
14.
When the beans reach the desired color /development,
move the Drum Door lever up to discharge the beans into
the Cooling Bin.
After the coffee has been in the Cooling Bin for a minute or
15.
so, turn off the "Agitator" (8) and spread out the coffee.
With the Agitator "OFF", the cool air can find a path through
16.
the beans allowing the coffee to cool faster.
When the beans have cooled to room temperature, position
17.
a container under the cooling bin chute.
Turn "ON" the "Agitator" (8), and discharge the beans from
18.
the Cooling Bin.
ROASTING FOR CONSUMPTION
crack" (~385°F), move the
st