High product customisation and quality repeatability over time are essential characteristics both for SMBs and for large companies. IMA Coffee Petroncini has developed the Roasting Director Suite, a versatile softwares’ panel that includes different kind of roasting control systems, each one tailored on specific type of productive needs and desired automation level: from the semi-automatic control MAESTRO Avantgarde with machine on-board operations, up to the full automatic OPERA 30 and ORCHESTRA, that can be managed on-board and by PC, easily integrated in the state-of-the art solutions for monitoring and controlling the overall production, with a detailed product traceability connected to the customer’s ERP systems. Every Control System can be combined with the ROASTING MANAGER, a unique dashboard for the roasting data.
MAESTRO is an easy-to-use, intuitive and reliable roasting control system to help the roast master handle roasting at his discretion. It can be operated directly at the roaster or via remote control.
MAESTRO Avantgarde combine the complete freedom of artisan roasting with the possibility of pre-setting the roasting recipes. MAESTRO allows the roast master to manage coffee temperature, drum rotation speed and air-to-bean ratio, therefore letting him vary the method of transferring heat to the bean, achieving the desired balance between convection and conduction. The temperatures and other parameters are shown in the trends summary, where the user can control roasting curve and current temperatures, monitoring the Rate-of-Rise and recording the first and second Crack temperatures in just one click. MAESTRO Avantgarde control includes the possibility to pre-set the different desired roasting profiles. The roast master can set up to 8 roasting steps for each roasting profile saved and register up to 20 roasting recipes in the system. The user can simply record and export the roasting profiles on a USB drive. MAESTRO Avantgarde allows for remote connectivity and remote assistance.
MAESTRO Pro control, a PC-based control system. In addition to the other features of MAESTRO Avantgarde, MAESTRO Pro enables the automatic memorization of the roast data and trends along with the possibility of analyzing the roasting results at any time in the preferred way, either on board directly or from PC. Furthermore, MAESTRO Pro control allows the roast master to save up to 99 freely definable recipes. Combined with MAESTRO Pro control, the PC-based application ROASTING MANAGER let the roast master collect and archive roasting production data and recipes over the years, summarizing data in a useful way with an attractive design. It enables to collect a back-up of almost 5 years of production.
OPERA30 is the ideal partner to have the full control of the roasting process, as the recipe creation and the roasting process monitoring are optimised. OPERA30 allows you to customize recipes and process parameters in a flexible and quick way, obtaining the desired sensory profiles with the guarantee of a perfect repeatability of the product quality over time. The roasting data and profiles are saved and available at any time within the system, and can be organized in the way you prefer thanks to the Roasting Manager, the new application integrated into OPERA30.
OPERA 30 traditional is available as standard with the TTA roaster models. This advanced control system allows you to set accurate roasting profiles and carry them out in subsequent cycles automatically, with the guarantee of a constant final product in terms of quality and sensory profiles. The system shows the preview of the stored roasting curves, comparing it with the actual rate-of-rise of the product in progress. Any profile modification during the process can be manually adapted by changing the product temperature and process parameters.
OPERA30 advanced is the answer to the need to obtain constant roasting results over time, especially for products such as pods and capsules, eliminating external influences such as the humidity of green coffee, the quantity of the batch entering the roaster and environmental variables. Proposed as an optional solution, OPERA30 advanced allows you to maintain full control of the roasting time, thanks to additional systems capable of compensating for any deviations from the expected roasting trend, automatically modulating the air and temperature according to the time set for the recipe.
The main features:
HIGH PROFITABILITY AND REPRODUCIBILITY
TMR roasting process ensures consistent degree of roast and roasting time, in order to reach the best bean quality consistency, despite of any affecting external conditions like production start- stop-restart, green coffee quality, coffee moisture, change of coffee lot. If the product temperature follows always the same profile, batch by batch, then the result will be consistent over the entire series. This is the reason why TMR is suitable for frequent recipe changes with a guaranteed repeatability. TMR gives the possibility to create innovative roasting profiles for new flavour characteristics and physical bean properties.
The roasting curves are previously drawn by setting the time and bean temperature as independent variables.
It is possible thanks to ORCHESTRA that allows to keep a consistent quality of the product right from the first batch, when the machine is cold, up to the last roasting cycle. Moreover, during the setting of the set-points, ORCHESTRA automatically evaluates the estimated end cycle time, with a maximum difference of 2 ÷ 3 seconds compared to the actual time at the end of the cycle. These features guarantee exactly the same final color, moisture and taste, day by day, during production.
In addition to the traditional control systems, ORCHESTRA allows you to pre-set roasting profiles according to a time-temperature logic, also controlling time as an independent variable of the process.
It is thus possible to maintain full control of the different roasting phases, determining the final characteristics of the coffee from the beginning.
ORCHESTRA also ensures the constant maintenance of the parameters of the individual roasting cycles, guaranteeing a final product that is always the same, repeatable and uniform.
ORCHESTRA therefore makes each roasting cycle independent from the chemical characteristics of green coffee (species, humidity and post-harvest treatments) and from environmental variables (temperature of the working rooms).
The main features:
During the setting of the various set-points, ORCHESTRA shows a simulation of the roasting profile that is being set, allowing the technologist to preview the final result; in case of modification of one or more parameters, ORCHESTRA superimposes the modified profile on the original one ensuring a quick visualization of the effects of the modifications made on the roasting profile. During the setting of the set-points, ORCHESTRA automatically evaluates the estimated end cycle time, with a maximum difference of 2 ÷ 3 seconds compared to the actual time at the end of the cycle.
Based on the selected roasting profile, ORCHESTRA will allow the product to reach the set temperatures, in the desired times, acting on the heat output of the burner and on the percentage of roasting fluid recirculated or integrated with fresh air.
This is made possible by the precise measurement of temperatures, carried out with continuous sampling, thanks to the special configuration of the roasters mod. TMR. The burner, modulating and specially sized according to the size of the roaster, responds extremely quickly to the regulation impulses sent to it by ORCHESTRA, compensating the heat supplied instantly with a power variation. The cold air valve is modulated by ORCHESTRA so that the product temperature coincides with that set in the profile.
The simultaneous management of the burner and the percentage of cold air re-integrated in the cycle also allows the burner to maintain the high temperatures necessary to reduce the fumes deriving from roasting.
During roasting, ORCHESTRA allows you to view the profile in progress superimposed on the profile set; thanks to the continuous modulations allowed by the control system managed by ORCHESTRA, these two profiles will overlap in the visualization of the roasting trend.
ROASTING MANAGER let the roast master collect and archive roasting production data and recipes over the years, summarising data in a useful way with an attractive design. It enables to collect a back-up of almost 5 years of production.
A UNIQUE DASHBOARD FOR YOUR DATA
All the roasts and process data are organised in the same place for a quick overview and analysis.
AT EVERY ROAST, ITS PROFILE
Roasting Manager can show the correspondent profile for every roast, either in a single view or compared with other roasts at the same time.
CUSTOMIzE THE DATA VIEW
You can filter all the data in the desired way: production date, recipe name, final temperature, green coffee moisture. Just with one click.