How is Instant Coffee Made? (From Bean To Powder)

Did you know that instant coffee makes up over a third of all the coffee consumed globally? I just learned this the other day, and honestly, I was surprised! For something that many people see as a “lesser” version of brewed coffee, instant coffee sure has a massive following.

The problem is that instant coffee often gets a bad rap for lacking that fresh and full flavor we love in our morning brew.

But here’s the thing—today’s instant coffee is far from what you might remember. Thanks to new processing techniques and premium blends, instant coffee is stepping up its game bit time.

In this guide, you’ll learn everything from how instant coffee is made, to the latest innovations that make it taste closer to freshly brewed coffee. Plus, we’ll dive into how the global demand for convenience is pushing brands to improve quality. So let’s bring it on…

Key Takeaways

• Instant Coffee’s Roots: Instant coffee was first created out of necessity, becoming especially popular during wartime for its convenience. Today, it’s a staple thanks to its simplicity and portability.
• How It’s Made: Instant coffee is created by brewing concentrated coffee, then using freeze-drying or spray-drying methods to make it shelf-stable. Freeze-drying retains more flavor, while spray-drying is faster and more economical.
• Rising Quality Standards: Modern instant coffee now includes premium options made from 100% Arabica beans and advanced techniques like micro-ground coffee, which makes the taste closer to freshly brewed.

Early Inventions and Experiments

The first experiments with instant coffee date back to the late 18th century! A British guy named John Dring took a crack at creating a “coffee compound” in 1771, which was one of the earliest attempts at making coffee powder.

But honestly? It didn’t really taste great. Back then, preserving that rich coffee aroma and flavor was a huge challenge, and his version didn’t capture that fresh-brewed taste we know today.

Then, in the early 1900s, along came a Japanese chemist named Sartori Kato. He made a significant breakthrough by refining the process of making powdered coffee. But again the flavor was still a challenge.

These early attempts often tasted pretty bland or overly bitter, which didn’t win people over.

World War Influence on Instant Coffee

Now, things really took a turn during World War I and II. Suddenly, instant coffee had a real purpose. For soldiers on the front lines, it was literally a lifesaver.

Imagine being stuck in trenches or on the battlefield; a hot, caffeinated drink could make a huge difference.

Plus, instant coffee was light, easy to carry, and didn’t need fancy brewing equipment. Military demand drove more innovation, which helped improve the taste bit by bit.

By the time the wars were over, manufacturers had figured out ways to make it more appealing, and it started catching on with everyday people back home.

Evolution to a Consumer Product Post-War

The post-war years were when things really picked up. Companies saw the potential of instant coffee as a consumer product. So they worked on making it tastier and more convenient. They introduced better processing techniques, eventually leading to the freeze-drying methods we see today.

And just like that, instant coffee moved from the trenches to our kitchen shelves, ready to go for a quick morning cup—or even for a trendy Dalgona coffee, if that’s more your style.

The Technology Evolution: From Spray Drying to Freeze Drying

The story of how we ended up with the freeze-dried coffee we know today is actually pretty interesting. Back in the 1930s, instant coffee was going through a bit of an identity crisis.

Brazil, the world’s largest coffee producer, was drowning in surplus coffee beans because of a slump in demand, and they desperately needed a solution.

That’s when Nestlé came into the picture. Brazil teamed up with Nestlé to figure out how to turn those beans into something that wouldn’t just go bad—and could be easily shipped and sold. So spray drying was the answer they came up with.

The Process of Spray Drying and Its Limitations

Now, this may sound complicated, but the process is fairly simple: they’d brew coffee, concentrate it, and then spray it into a high-heat chamber.

This heat caused the liquid to evaporate and leave behind a powder. But the problem is high heat isn’t exactly kind to coffee’s flavor. A lot of those beautiful, rich aromas? Gone. What was left tasted, well, kind of flat.

Consumers weren’t thrilled, but it was a start. Spray-dried coffee became popular out of necessity, but it was clear that the taste needed some serious improvement.

The Transition to Freeze Drying: A Modern Solution

Then came freeze-drying, which changed the game completely. Unlike spray drying, freeze drying uses cold temperatures to preserve all those delicate flavors that make coffee what it is.

Here’s how it works:

They start by brewing the coffee and then reducing it to a concentrated liquid. This liquid is frozen solid at around -40°C, then broken into small granules.

These frozen pieces go through a low-temperature drying process. So, instead of using heat, the moisture is removed through sublimation (basically, ice turning directly to vapor). It’s a much gentler process that keeps those amazing coffee aromas intact.

Spray-Dried vs. Freeze-Dried Coffee: Flavor Differences

I am going to compare both to show you more clearly the difference between flavor and other qualities.

Aspect	Spray-Dried Coffee	Freeze-Dried Coffee
Flavor	Tends to have a slightly burnt, flat taste	Richer, closer to freshly brewed coffee
Aroma	Many delicate aromas are lost during high-heat drying	Better aroma retention due to low-temperature drying
Texture	Often results in a finer powder	Produces larger, more uniform granules
Drying Temperature	High temperatures used, typically around 150-200°C	Very low temperatures (around -40°C)
Preservation of Compounds	High heat degrades some of the coffee’s essential oils	Retains more volatile compounds, enhancing flavor
Appearance	Fine, sometimes dusty powder	Coarser, chunkier granules
Production Efficiency	Faster and more cost-effective	More time-intensive and costly
Shelf Life	Slightly shorter due to some residual moisture absorption	Generally longer due to lower moisture content

How They Make Instant Coffee Powder Nowadays?

Now let’s talk about each step to see how instant coffee powder is made today.

Step 1: Coffee Bean Selection and Roasting

Often manufacturers choose robusta beans for instant coffee because they have a higher caffeine content and a stronger flavor that holds up well during processing.

Also, robusta beans are commonly cheaper, so it’s a win-win. Once they’ve got the beans, it’s all about the roast.

The beans are roasted to a medium or dark level. This gives that classic, rich coffee aroma and flavor we all expect. However, roasting also affects how the coffee will taste once it’s processed into powder.

If the roast is too light, the coffee ends up tasting weak. Otherwise, it’s too dark, and it might be overly bitter.

Step 2: Grinding and Brewing

After roasting, the beans are ground to a specific size. For instant coffee, they don’t go for the super-fine grind you’d see in espresso. But it’s still finer than your average drip coffee. Grinding to the right texture helps extract all those deep flavors during brewing.

Next comes the brewing part. Just like you might brew a strong cup at home, these grounds are brewed to make a highly concentrated coffee extract.

They’re not making a mild coffee here; it’s brewed strong to make sure the final product has enough flavor to stand up to the drying process.

Imagine brewing coffee with, say, twice as much ground coffee as you usually would—that’s how strong this concentrate ends up being.

Step 3: Concentration and Extraction

Now, with that concentrated coffee in hand, the next step is to reduce it even more. For this, they remove some of the water to turn it into a thicker extract.

This step is all about getting the right balance; too watery, and you’ll lose flavor in the final powder; too thick, and it becomes harder to process.

One challenge here is keeping those essential coffee oils and aromatic compounds intact. These compounds give coffee its rich taste and smell.

But they’re fragile and can evaporate easily. So manufacturers use different techniques to protect them during extraction. For instance, they carefully control the temperature and time to get that freshly brewed taste in your cup later.

Step 4: Freeze Drying Process

Now comes the freeze-drying process, which is where instant coffee truly starts to look like, well, instant coffee.

First, they freeze the concentrated coffee extract at a very low temperature—around -40°C! Freezing the coffee solid preserves all those complex flavors and aromas.

Once frozen, the coffee is broken down into small and uniform granules. These chunks then go through a freeze-drying chamber where moisture is removed through sublimation (that’s when ice turns directly into vapor without melting).

This step is slow, but it’s worth it because it’s the secret to maintaining that rich coffee taste. By the end, you’ve got dry, flavorful coffee granules that just need hot water to rehydrate.

Step 5: Adding Aroma and Flavor

Finally, there’s a bit of a finishing touch that makes instant coffee more like a freshly brewed cup.

Some of the aromatics lost earlier in the process are added back at this stage. Often they use caffeol, an oil from the coffee grounds, to give instant coffee that fresh coffee aroma.

Just a light spritz over the granules, and it smells and tastes much closer to what you’d get from a traditional brew.

Global Market and Consumer Demand for Instant Coffee

The instant coffee market has been expanding rapidly in recent years, and it’s easy to see why—people love convenience!

The instant coffee market was valued at around $32.9 billion in 2022, and it’s projected to nearly double to $60.7 billion by 2032, growing at a rate of 6.4% per year.

This growth is largely driven by single-serve packaging, premium options, and increased coffee demand across developed and emerging markets.

Emerging Markets and Cultural Perceptions

For example, in China, Nestlé’s launch of Starbucks-branded instant coffee mini-cans has opened the market to premium instant options.

Consumers in these areas are getting exposure to global coffee trends and showing interest in more “specialty” options, like freeze-dried Arabica coffee or 3-in-1 instant packs that include creamers and sweeteners.

In India, brands like Tata and Sleepy Owl have introduced premium lines to attract consumers who want a better taste without the coffee shop price.

The Future of Instant Coffee

Over the past few decades, we’ve seen a massive improvement in the quality of instant coffee—starting with spray drying, then freeze-drying, and even microground coffee, which added a richness that hadn’t been possible before.

But now, it seems we’re entering a whole new era, with innovations starting to blur the line between instant coffee and fresh-brewed.

New Exciting Innovations…

One of the most exciting developments is Sensoria by Buencafé, a next-generation instant coffee that’s being called the closest thing to freshly brewed coffee.

Made with premium Colombian Arabica beans, Sensoria uses a multistage freeze-drying process that captures natural flavors and aromas better than ever.

This method, which focuses on early aroma recovery and dynamic extraction, retains the intense, complex flavors you’d expect from roast-and-ground coffee.

The result is a cup of instant coffee with a depth and richness that’s hard to distinguish from the real deal.

Last Thoughts

And there you have it—an inside look at the world of instant coffee, from its origins to the fascinating innovations shaping its future!

Instant coffee has come a long way, proving that convenience and flavor don’t have to be at odds.

But now, I’m curious—what’s your take on instant coffee? Are you a fan, or do you stick to freshly brewed? So drop a comment below and let me know your favorite know your favorite way to enjoy coffee, instant or otherwise!