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This study aimed to develop a process for producing instant coffee from cold brewed Arabica and Robusta roasted coffee beans. The process starts by selecting an appropriate mixture of Arabica and Robusta coffee beans, degree of roasting (light, medium, dark) and degree of grinding (coarse, fine). Sensory evaluation by a trained panel showed that a mixture of 92.5% Arabica and 7.5% Robusta medium roasted, coarsely ground coffee beans produces instant cold brewed coffee equally or better accepted from other instant coffees available to consumers. The selected coffee beans were subjected to vacuum assisted cold extraction and the extract was spray dried. Spray drying conditions (inlet temperature, air volumetric flow and air aspiration rate) were optimized by a 33 full factorial design. Response variables were solids yield, process thermal efficiency and anti-oxidant capacity of the produced powder measured as %DPPH scavenging ability, FRAP and total phenolic content. The produced powder was analysed for its physicochemical characteristics (caffeine content, phenolics, moisture content, hygroscopicity, bulk density, solubility, particle size distribution, acrylamide content and shelf life determination).
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