Circular Economy and Climate

Page 35-36: Cascara Production & Standards

Page 35: Cascara Processing and Quality Control

What is Cascara?

Definition and Origins:

· Terminology: “Cascara” means “husk” or “peel” in Spanish
· Product: Dried skins and pulp of coffee cherries
· Traditional Use: Historically consumed in coffee-growing regions as a tea-like infusion
· Modern Rediscovery: Specialty coffee industry innovation since early 2000s

Chemical Composition:

· Moisture Content: <12% for stable storage
· Soluble Solids: 15-25% (extractable compounds)
· Key Components:
· Caffeine: 0.5-1.5% (lower than coffee beans)
· Antioxidants: High in chlorogenic acids (2-4%)
· Minerals: Potassium (3-4%), Magnesium (0.2-0.4%), Calcium (0.3-0.5%)
· Sugars: Fructose, glucose, sucrose (15-20% total)
· Dietary Fiber: 25-35%
· Pectin: 5-10% (gelling agent potential)

Food Safety Considerations:

Critical Control Points:

1. Microbial Contamination Risks:

· Sources: Soil, processing water, handling, drying surfaces
· Pathogens of Concern:
· E. coli O157:H7 (fecal contamination)
· Salmonella spp. (animal/human contamination)
· Aspergillus spp. (mycotoxin producers)
· Yeasts and molds (spoilage organisms)

2. Chemical Contaminants:

· Pesticide Residues: From coffee farming
· Mycotoxins: Ochratoxin A, aflatoxins (from improper drying)
· Heavy Metals: From contaminated soil or water
· Processing Chemicals: Cleaning agents, lubricants

3. Physical Contaminants:

· Foreign Matter: Stones, soil, metal fragments
· Biological: Insects, rodent hairs, excrement
· Processing Residues: Parchment fragments, defective beans

Processing Protocols:

Step 1: Harvest and Immediate Handling

Optimal Harvest Timing:

· Cherry Selection: Fully ripe cherries (deep red color)
· Avoid: Over-ripe (fermenting), under-ripe (green), damaged cherries
· Timing: Process within 4-6 hours of harvest

Initial Sorting and Cleaning:

1. Float Test: Remove floaters (immature, defective cherries)
2. Visual Inspection: Remove foreign matter, damaged cherries
3. Washing (optional): Clean water rinse if soil contamination suspected
   · Water Quality: Potable water, chlorine <5 ppm if used
   · Drying: Immediate drying after washing to prevent fermentation

Step 2: Pulping and Pulp Separation

Pulping Methods:

Traditional Wet Processing Pulping:

· Equipment: Standard coffee pulpers
· Advantage: Already available at processing stations
· Challenge: Pulp mixed with some parchment and beans

Specialized Cascara Pulping:

· Modified Pulpers: Adjusted to minimize bean damage
· Pulp Recovery: Screens or sieves to separate pulp from beans
· Yield: 40-45% of fresh cherry weight as wet pulp

Quality Considerations During Pulping:

· Avoid Bean Contamination: Minimize broken beans in pulp
· Temperature Control: Pulp heats during mechanical pulping
· Immediate Processing: Process pulp immediately after separation

Step 3: Washing and Mucilage Removal

Traditional Method (Fermentation Removal):

· Not Recommended for Cascara: Can develop off-flavors, microbial risks
· If Used: Maximum 12 hours, monitor temperature (<30°C)

Mechanical Demucilaging:

· Equipment: Modified pulpers with brushing action
· Advantage: No fermentation, consistent quality
· Disadvantage: Additional equipment investment

Water-Assisted Removal:

· Method: Gentle agitation in clean water
· Time: 1-2 hours maximum
· Water: Clean, potable water, changed frequently
· Final Rinse: Clean water to remove residual mucilage

Step 4: Drying Protocols

Critical Parameters:

· Initial Moisture: 75-80% (wet pulp)
· Target Moisture: 10-12% for storage
· Drying Temperature: 40-50°C maximum
· Drying Time: 24-48 hours depending on method

Drying Methods:

1. Solar Drying (Recommended for Small Scale):

Raised Bed Solar Dryers:

· Construction: Wooden frame with mesh bottom (stainless steel or food-grade plastic)
· Dimensions: 2m × 1m × 0.3m (height for air circulation)
· Cover: UV-stabilized polycarbonate or glass
· Layer Thickness: 2-3cm maximum
· Turning: Every 2-3 hours for even drying
· Protection: Insect screens on sides

Direct Sun Drying (if no alternative):

· Risks: Contamination (dust, insects, birds), uneven drying, rain damage
· If Used:
· Clean tarpaulin or food-grade plastic sheets
· Frequent turning (hourly)
· Cover at night or if rain threatens
· Maximum 2-3 days to prevent spoilage

2. Mechanical Drying (Commercial Scale):

Tray Dryers:

· Temperature Control: 45-50°C with dehumidification
· Air Flow: 0.5-1.0 m/s across trays
· Tray Loading: 5-10kg/m²
· Advantages: Consistent quality, weather independent
· Investment: $5,000-20,000 for small unit

Tunnel Dryers:

· Capacity: 100-500kg per batch
· Temperature Gradient: 50°C inlet, 40°C outlet
· Drying Time: 8-12 hours
· Use: Larger cascara operations

3. Hybrid Systems:

· Solar-Assisted Mechanical: Solar pre-heating of air
· Phase Drying: Solar for initial drying, finish with mechanical

Moisture Monitoring:

Methods:

1. Moisture Meter (capacitance type):
   · Calibrate for cascara
   · Test multiple samples from different locations
   · Target: 10-12%
2. Manual Tests:
   · Bend Test: Dry cascara should snap, not bend
   · Color: Uniform dark red/brown, no light or moist spots
   · Texture: Crisp, not leathery or tacky

Step 5: Final Processing and Grading

Cleaning and Sorting:

1. Sieving: Remove fine particles, dust
2. Air Classification: Remove lightweight foreign matter
3. Color Sorting (commercial scale): Remove discolored pieces
4. Manual Inspection: Final quality check

Size Classification (Optional):

· Whole: Large pieces (>5mm)
· Broken: Medium pieces (2-5mm)
· Fine: Small pieces (<2mm) – often for tea bags

Quality Grading System:

Grade A (Premium):

· Color: Uniform dark red to burgundy
· Aroma: Strong fruity, floral notes
· Freedom from Defects: <2% foreign matter
· Moisture: 10-11%
· Cup Quality: Clean, bright, complex infusion

Grade B (Commercial):

· Color: Slight variation allowed
· Aroma: Good fruit notes, may have some earthy tones
· Freedom from Defects: <5% foreign matter
· Moisture: 10-12%
· Cup Quality: Good flavor, may have some imperfections

Grade C (Industrial/Extraction):

· Color: Variable
· Aroma: Basic fruit notes
· Freedom from Defects: <10% foreign matter
· Moisture: 8-12%
· Use: For extracts, flavorings, blending

Page 36: Cascara Standards, Markets, and Regulations

Food Safety Standards and Certification:

Global Regulatory Status:

Novel Food Considerations:

· EU: Cascara was considered Novel Food until 2022
· Current Status: Now approved for consumption with specified conditions
· USA: Generally Recognized as Safe (GRAS) status for some applications
· Other Markets: Varies by country – research required before export

Required Food Safety Certifications:

1. Good Manufacturing Practices (GMP):

· Facility Requirements:
· Cleanable surfaces (non-porous)
· Separation of raw and finished product areas
· Pest control program
· Employee hygiene facilities
· Documentation: Standard Operating Procedures (SOPs) for all processes

2. Hazard Analysis Critical Control Points (HACCP):

HACCP Plan Development:

1. Hazard Analysis:
   · Biological (pathogens, molds)
   · Chemical (pesticides, mycotoxins, cleaning chemicals)
   · Physical (foreign materials)
2. Critical Control Points (CCPs) for Cascara:

CCP 1: Raw Material Receipt

· Hazard: Pesticide residues, microbial contamination
· Control: Supplier approval, certificate of analysis
· Monitoring: Incoming inspection, testing
· Corrective Action: Reject contaminated lots

CCP 2: Drying Process

· Hazard: Microbial growth, mycotoxin formation
· Control: Temperature (<50°C), time (<48 hours), final moisture (<12%)
· Monitoring: Temperature logs, moisture testing
· Corrective Action: Adjust drying parameters, reprocess if needed

CCP 3: Metal Detection

· Hazard: Metal fragments from equipment
· Control: Metal detector at packaging
· Monitoring: Check every hour, test pieces
· Corrective Action: Investigate source, adjust equipment

1. Verification Procedures:
   · Microbial testing (monthly)
   · Pesticide residue testing (annually)
   · Mycotoxin testing (biannually)
   · Audit of HACCP system (annually)
2. Organic Certification (if applicable):

· Requirements:
· Coffee grown without synthetic inputs for 3+ years
· Processing without prohibited substances
· Documentation of organic chain of custody
· Certification Bodies: EU Organic, USDA Organic, JAS (Japan), etc.

4. Fair Trade/Sustainability Certifications:

· Compatibility: Cascara can be included in coffee certification
· Premium: May qualify for sustainability premiums
· Documentation: Additional record-keeping for product tracing

Quality Standards and Specifications:

Physical Specifications:

Moisture Content:

· Target: 10-12%
· Maximum: 13% (for safe storage)
· Testing: Moisture meter or oven method
· Frequency: Each batch

Foreign Matter:

· Maximum Allowable:
· Grade A: <2%
· Grade B: <5%
· Grade C: <10%
· Types: Soil, stones, metal, insect parts, etc.
· Testing: Visual inspection, sieving

Particle Size Distribution (for specific markets):

· Whole: >5mm: 70% minimum
· Broken: 2-5mm: 20% maximum
· Fines: <2mm: 10% maximum

Chemical Specifications:

Microbiological Limits:

· Total Plate Count: <10⁴ CFU/g
· Yeast and Mold: <10² CFU/g
· E. coli: Absent in 1g
· Salmonella: Absent in 25g

Mycotoxin Limits:

· Ochratoxin A: <5 μg/kg (EU standard)
· Aflatoxins (total): <4 μg/kg (EU standard)
· Testing: HPLC or ELISA methods
· Frequency: At least biannually, more if risk factors present

Pesticide Residues:

· Maximum Residue Limits (MRLs): Vary by country
· EU MRLs: Apply to cascara as a “tea-like” product
· Testing: Multi-residue screens (100+ pesticides)
· Frequency: Annual, or per batch for new suppliers

Heavy Metals:

· Lead: <0.5 mg/kg
· Cadmium: <0.1 mg/kg
· Arsenic: <0.5 mg/kg
· Mercury: <0.05 mg/kg

Caffeine Content:

· Typical Range: 0.5-1.5%
· Labeling Requirement: In some markets if >150mg/serving
· Testing: HPLC standard method

Sensory Specifications:

Cupping Protocol for Cascara:

Preparation:

· Ratio: 15g cascara : 250ml water (6% extraction)
· Water Temperature: 94-96°C (just off boil)
· Steep Time: 4 minutes
· Vessel: Pre-heated ceramic or glass

Evaluation Criteria:

1. Fragrance/Aroma (Dry/Wet):

· Desirable: Red fruit (cherry, raspberry), floral (rose, hibiscus), sweet (brown sugar, honey)
· Undesirable: Earthy, moldy, fermented, chemical

2. Flavor:

· Acidity: Bright, wine-like (positive) vs. sour, vinegar-like (negative)
· Sweetness: Natural fruit sweetness vs. cloying or absent
· Body: Light to medium, tea-like texture
· Aftertaste: Clean, pleasant finish vs. astringent, bitter

3. Defects:

· Primary: Moldy, fermented, phenolic
· Secondary: Earthy, woody, papery

Scoring System (adapted from coffee cupping):

· 90-100: Exceptional, complex, no defects
· 85-89.99: Very good, distinctive character
· 80-84.99: Good, commercial quality
· Below 80: Below specialty standard

Packaging and Storage:

Packaging Requirements:

Barrier Properties Needed:

1. Moisture Barrier: Water vapor transmission rate <1g/m²/day
2. Oxygen Barrier: Oxygen transmission rate <10cm³/m²/day
3. Light Protection: Opaque or UV-blocking materials
4. Aroma Preservation: Low permeability to volatile compounds

Packaging Options:

Primary Packaging (direct contact with cascara):

1. Foil Laminated Pouches:
   · Structure: PET/AL/PE or PET/AL/NY/PE
   · Advantages: Excellent barrier, can be gas flushed
   · Cost: $0.10-0.30 per 100g pouch
2. Metalized Pouches:
   · Structure: PET/MPET/PE
   · Advantages: Good barrier, lower cost than foil
   · Cost: $0.05-0.15 per 100g pouch
3. Glass Jars:
   · Advantages: Excellent barrier, reusable, premium appearance
   · Disadvantages: Heavy, fragile, higher shipping cost
4. Tin Ties:
   · Advantages: Resealable, moderate barrier
   · Disadvantages: Limited shelf life once opened

Secondary Packaging (for transport and display):

· Corrugated Boxes: Food-grade, moisture-resistant coating
· Display Boxes: For retail presentation
· Shipper Boxes: For bulk transport

Labeling Requirements:

Mandatory Information:

1. Product Name: “Cascara” or “Coffee Cherry Tea”
2. Ingredients: 100% dried coffee cherry pulp
3. Net Weight
4. Origin: Country of origin (e.g., “Product of Kenya”)
5. Lot/Batch Number
6. Best Before Date (typically 12-18 months from production)
7. Storage Instructions: “Store in a cool, dry place”
8. Preparation Instructions
9. Caffeine Content (if required in market)
10. Business Name and Address

Optional Information:

· Flavor Notes: Tasting description
· Story: Information about production, farmers
· Certification Logos: Organic, Fair Trade, etc.
· Brewing Suggestions: Alternative preparation methods

Storage Conditions:

Optimal Storage Parameters:

· Temperature: 15-20°C (59-68°F)
· Relative Humidity: <60%
· Light: Dark storage
· Odors: Separate from strong-smelling products

Shelf Life:

· Under Optimal Conditions: 18-24 months
· Commercial Reality: 12 months typical shelf life
· Factors Reducing Shelf Life: High moisture, temperature fluctuations, light exposure

Warehouse Management:

· First In, First Out (FIFO): Inventory rotation system
· Pest Control: Regular inspections, bait stations if needed
· Temperature Monitoring: Data loggers for quality assurance
· Separation: From non-food items, cleaning chemicals

Market Analysis and Commercialization:

Market Segments:

1. Specialty Coffee Sector:

· Customers: Third-wave coffee shops, specialty retailers
· Product Forms: Loose leaf, tea bags, ready-to-drink (RTD)
· Price Point: Premium ($30-50/kg wholesale)
· Requirements: Traceability, story, quality consistency

2. Health Food/Natural Products:

· Customers: Health-conscious consumers, natural food stores
· Product Forms: Tea bags, extracts, supplements
· Price Point: Medium-high ($20-40/kg)
· Requirements: Organic certification, health benefits messaging

3. Food Service:

· Customers: Restaurants, hotels, cafés
· Product Forms: Bulk loose leaf, food ingredients
· Price Point: Medium ($15-30/kg)
· Requirements: Consistent supply, food safety documentation

4. Industrial/Ingredient Market:

· Customers: Food manufacturers, extract companies
· Product Forms: Bulk powder, extracts
· Price Point: Low-medium ($10-20/kg)
· Requirements: Large volumes, consistent specifications

Global Market Trends:

Growth Drivers:

1. Consumer Interest: Novelty, health benefits, sustainability story
2. Sustainability: Upcycling waste stream appeals to conscious consumers
3. Health Trends: Natural caffeine source, antioxidant content
4. Flavor Innovation: Unique flavor profile for beverage developers

Market Challenges:

1. Regulatory Uncertainty: Varies by country, changing regulations
2. Seasonal Supply: Coffee harvest seasonality affects cascara availability
3. Quality Consistency: Difficult to standardize agricultural product
4. Consumer Education: Still relatively unknown product

Pricing Structure:

Farm Gate Price (to processor):

· Fresh Pulp: $0.10-0.30/kg (depending on quality, volume)
· Dried Cascara: $2-5/kg (10:1 drying ratio)

Wholesale Price (processed, packaged):

· Grade A: $30-50/kg
· Grade B: $20-30/kg
· Grade C: $10-20/kg

Retail Price:

· Loose Leaf: $50-100/kg ($5-10/100g package)
· Tea Bags: $0.50-1.00 per bag
· RTD Beverages: $3-5 per 300ml bottle

Value Chain Economics Example (100kg dried cascara):

Costs:

· Fresh pulp purchase (1,000kg @ $0.20/kg): $200
· Processing (labor, energy, water): $300
· Packaging (primary + secondary): $200
· Testing and certification: $100
· Overhead (facility, management): $200
· Total Cost: $1,000 ($10/kg)

Revenue:

· Grade A (60kg @ $40/kg): $2,400
· Grade B (30kg @ $25/kg): $750
· Grade C (10kg @ $15/kg): $150
· Total Revenue: $3,300 ($33/kg)

Gross Profit: $2,300 (70% margin)

Case Study: Successful Cascara Enterprise in Costa Rica

Company: Café de Cascara S.A.
Location:Central Valley, Costa Rica
Established:2018
Scale:Processes pulp from 50 smallholder farms (200 hectares total)

Key Success Factors:

1. Quality-Focused Partnerships:

· Farmer Training: Cascara-specific harvest and handling protocols
· Premium Pricing: 20% above market for perfect ripe cherries
· Daily Collection: Prevents fermentation, ensures freshness

2. Advanced Processing:

· Facility: Purpose-built cascara processing plant
· Technology: Solar-assisted mechanical dryers with humidity control
· Quality Lab: In-house testing for moisture, microbiology, pesticides

3. Market Development:

· Brand Story: “Rescued Coffee Cherry” narrative
· Product Range: Three grades for different markets
· Export Focus: 70% exported to USA, Europe, Japan

Results (2022):

· Volume: 8,000kg dried cascara
· Revenue: $240,000 (average $30/kg)
· Farmer Income: Additional $40,000 to supplying farmers
· Employment: 12 full-time positions created
· Waste Reduction: Diverted 80 tons pulp from waste streams

Certifications Achieved:

· USDA Organic
· Fair Trade
· HACCP
· Carbon Neutral (through offsets)

G4T Standards for Cascara Production:

Minimum Requirements:

1. Food Safety: Basic GMP implemented, no critical violations
2. Quality Control: Moisture testing each batch, visual inspection
3. Traceability: Batch records from farm to final product
4. Fair Pricing: Farmers receive fair price for pulp/cascara

Premium Requirements:

1. Certified Food Safety: HACCP or equivalent certification
2. Comprehensive Testing: Regular microbial, mycotoxin, pesticide testing
3. Value Addition: Multiple product forms (loose leaf, tea bags, extracts)
4. Market Development: Success in export or premium domestic markets
5. Farmer Partnership: Profit-sharing or equity models with supplying farmers

Practical Exercise: Cascara Business Development Plan

Participants develop a cascara business plan:

1. Supply Chain Design:
   · Source identification (own farm, cooperative, multiple farms)
   · Collection system design (frequency, transport, quality checks)
   · Supplier agreements and pricing structure
2. Processing Facility Plan:
   · Site selection and layout
   · Equipment specification and sourcing
   · Flow diagram from receipt to dispatch
   · Capacity planning and expansion strategy
3. Quality Management System:
   · SOP development for each process step
   · Testing protocols and frequency
   · Documentation and record-keeping system
   · Corrective action procedures
4. Market and Sales Strategy:
   · Target market identification
   · Product portfolio (grades, packaging options)
   · Pricing strategy by market segment
   · Distribution channels and partners
5. Financial Projections:
   · Capital investment requirements
   · Operating costs (fixed and variable)
   · Revenue projections by product/market
   · Break-even analysis
   · Return on investment timeline
6. Risk Management Plan:
   · Identification of key risks (supply, quality, market, regulatory)
   · Mitigation strategies for each risk
   · Contingency plans for major disruptions
   · Insurance requirements

This comprehensive approach to cascara production transforms a waste product into a valuable commodity while creating new income streams, reducing environmental impacts, and diversifying coffee farming enterprises.

Page 37-38: Spent Grounds Valorization

Page 37: Commercial Applications of Spent Coffee Grounds

Learning Objectives:

1. Identify high-value commercial applications for spent coffee grounds (SCG)
2. Understand processing requirements for different SCG applications
3. Evaluate market potential and business models for SCG valorization

Characteristics of Spent Coffee Grounds:

Global Production Estimates:

· Annual Generation: 6 million tons worldwide
· Sources:
· Commercial cafés: 5-10 kg/day per location
· Households: Accumulated small quantities
· Instant coffee factories: Large concentrated volumes
· Office coffee stations: Regular small volumes
· Current Disposition: 75% to landfill, 20% composted, 5% valorized

Chemical Composition Analysis (dry basis):

Proximate Analysis:

· Moisture: 50-65% as discarded (post-brewing)
· Volatile Matter: 70-80%
· Fixed Carbon: 15-20%
· Ash: 1-3%

Elemental Analysis:

· Carbon: 50-60%
· Hydrogen: 6-7%
· Nitrogen: 2-2.5%
· Oxygen: 25-30%

Nutrient Content:

· Total Nitrogen: 2.0-2.5%
· Phosphorus (as P₂O₅): 0.3-0.5%
· Potassium (as K₂O): 0.5-1.0%
· C:N Ratio: 20-25:1 (ideal for composting)

Lipid/Oil Content:

· Total Extractable Oil: 10-20% of dry weight
· Composition:
· Palmitic acid: 30-40%
· Linoleic acid: 40-50%
· Oleic acid: 5-10%
· Stearic acid: 5-10%
· Applications: Cosmetics, biodiesel, lubricants

Fiber Content:

· Total Dietary Fiber: 50-60%
· Soluble Fiber: 5-10%
· Insoluble Fiber: 40-50%
· Applications: Food fortification, functional ingredients

Bioactive Compounds:

· Antioxidants: Residual phenolic compounds
· Caffeine: 0.5-1.5% residual
· Applications: Cosmetics, supplements, functional foods

Physical Properties:

· Bulk Density: 200-300 kg/m³ (as discarded)
· Particle Size: 0.1-1.0 mm (varies by grind)
· pH: 5.5-6.5 (slightly acidic)
· Water Holding Capacity: 3-5 g water/g dry SCG

Collection and Pre-processing:

Collection System Design:

Source-Specific Strategies:

1. Café Collection Systems:

· Container Design:
· Food-grade plastic with tight lids
· 20-30L capacity (manageable weight when full)
· Clearly labeled “Coffee Grounds Only”
· Collection Schedule: Daily or every other day
· Incentives for Participation:
· Free collection service
· Discount on valorized products
· Sustainability certification/recognition

2. Office/Institutional Collection:

· Centralized System: Designated collection points
· Education: Clear instructions on what can be collected
· Logistics: Regular pickup schedule

3. Household Collection:

· Drop-off Points: At participating cafés or collection centers
· Community Collection Events: Monthly or quarterly
· Incentives: Product discounts, community garden compost

Pre-processing Requirements:

1. Dewatering (if collected wet):

· Methods:
· Simple pressing: Manual or hydraulic press
· Centrifugation: Small-scale centrifuges
· Gravity drainage: Perforated containers
· Target: Reduce moisture to 60-65% for transport/storage

2. Drying (for certain applications):

· Methods:
· Solar drying: Low-cost, weather dependent
· Mechanical drying: Rotary dryers, belt dryers
· Combined systems: Solar pre-drying, mechanical finish
· Target Moisture by Application:
· Extraction processes: <10%
· Composting: 50-60% (optimal)
· Fuel briquettes: <15%

3. Storage Considerations:

· Short-term (<1 week): Covered containers, cool location · Medium-term (1-4 weeks): Refrigerated or dried · Long-term (>1 month): Dried to <10% moisture, sealed containers
· Prevention of Mold: Adequate airflow, moisture control

4. Contamination Control:

· Separation: Keep SCG separate from other waste
· Training: Collection staff and source education
· Inspection: Visual check for contaminants
· Processing: Sieving, magnetic separation if needed

Commercial Applications and Processing:

Application 1: Cosmetics and Personal Care

Market Overview:

· Size: Global natural cosmetics market >$30 billion
· Growth: 8-10% annually
· SCG Value Proposition: Natural exfoliant, antioxidant source, upcycled ingredient

Key Products:

1. Coffee Scrubs:

· Formulation:
· Base: SCG (30-50%)
· Carrier oils: Coconut, jojoba, almond (40-60%)
· Additives: Essential oils, honey, salt/sugar (5-10%)
· Processing:
· SCG preparation: Dried (<10% moisture), sterilized
· Particle size: Uniform 0.2-0.5mm (optional grinding/sieving)
· Blending: Gentle mixing to preserve particle integrity
· Packaging: Moisture-resistant containers, 100-500g sizes
· Market Price: $20-50/kg finished product

2. Soap with Coffee Grounds:

· Function: Exfoliation, natural color, caffeine absorption potential
· Formulation: 5-10% SCG in soap base
· Processing: Cold process or melt-and-pour methods
· Market Price: $5-15 per bar

3. Face Masks and Creams:

· Active Components: Antioxidants, caffeine (reduced puffiness)
· Extraction Methods:
· Solvent extraction (ethanol, glycerin)
· Supercritical CO₂ extraction (premium)
· Water extraction (simpler)
· Market Price: Extract $100-500/kg, finished products $30-100/kg

Quality Requirements for Cosmetics:

· Microbiological: Total plate count <1000 CFU/g, pathogens absent
· Particle Size: Consistent, not too abrasive
· Stability: No separation, rancidity prevention
· Regulatory: Compliance with cosmetics regulations (varies by country)

Application 2: Bio-briquettes and Solid Fuel

Market Overview:

· Need: Alternative to charcoal/wood fuel in urban areas
· Advantages: Higher calorific value than wood, renewable
· Challenges: Competing with subsidized fossil fuels

Briquette Production Process:

1. Raw Material Preparation:

· Drying: To 10-15% moisture
· Size Reduction: Hammer mill to 1-3mm particles
· Optional Additives:
· Binders: Cassava starch (5-10%)
· Other biomass: Sawdust, agricultural residues (for blending)

2. Briquetting Methods:

Piston Press:

· Pressure: 100-150 MPa
· Briquette Shape: Cylindrical, hollow center
· Capacity: 50-200 kg/hour
· Energy: 30-50 kWh/ton
· Investment: $5,000-20,000

Screw Extruder:

· Pressure: Lower than piston
· Briquette Shape: Continuous extrudate, cut to length
· Capacity: 100-300 kg/hour
· Energy: 40-60 kWh/ton
· Investment: $10,000-30,000

3. Drying and Curing:

· Solar Drying: 2-3 days in good weather
· Mechanical Drying: 24-48 hours at 60-80°C
· Target Moisture: <10% for storage

Fuel Properties:

· Calorific Value: 18-20 MJ/kg (compared to wood: 15-17 MJ/kg)
· Ash Content: 1-3% (lower than many biomass fuels)
· Burning Time: Longer than equivalent wood charcoal
· Smoke Production: Lower than raw biomass

Market Considerations:

· Price Point: $0.50-1.00/kg (competitive with charcoal)
· Packaging: Moisture-proof bags, 2-10kg sizes
· Target Markets: Urban households, restaurants, institutions

Application 3: Mushroom Cultivation Substrate

Technical Basis:

· Nutrition: SCG provides nitrogen, minerals, some carbohydrates
· Physical Structure: Good water retention, aeration
· Common Mushrooms: Oyster mushrooms (Pleurotus spp.) most compatible

Substrate Formulation:

Basic Recipe:

· SCG (wet basis): 70%
· Straw or sawdust: 25%
· Wheat bran or rice bran: 5%
· Lime: 1% (to adjust pH)

Advanced Recipes (for higher yield):

· SCG: 60%
· Sawdust (hardwood): 30%
· Wheat bran: 8%
· Gypsum: 1%
· Lime: 1%

Processing Steps:

1. Pasteurization or Sterilization:

· Hot Water Pasteurization: 70-80°C for 1-2 hours
· Steam Sterilization: 121°C for 1 hour (for pure cultures)
· Lime Treatment: Soak in pH 12 water for 12-24 hours

2. Inoculation:

· Spawn Rate: 5-10% of substrate weight
· Mixing: Thorough but gentle to distribute spawn
· Containers: Polypropylene bags with filter patches

3. Incubation:

· Temperature: 20-25°C
· Time: 2-3 weeks for full colonization
· CO₂ Levels: High CO₂ encourages mycelial growth

4. Fruiting:

· Conditions: Lower temperature (15-20°C), higher humidity (80-90%)
· Light: Indirect light needed for pinning
· Fresh Air Exchange: Essential for mushroom development

Yield Expectations:

· Biological Efficiency: 60-100% (kg mushrooms per kg dry substrate)
· Harvest Period: 3-4 flushes over 6-8 weeks
· Total Yield: 300-500g mushrooms per kg initial wet substrate

Economic Analysis (Small-scale: 100kg substrate/week):

· Input Costs: SCG (free), supplements ($20), spawn ($30), bags ($10)
· Labor: 10 hours @ $5/hour = $50
· Total Weekly Cost: $110
· Yield: 30-50kg mushrooms
· Revenue: 40kg @ $5/kg = $200
· Weekly Profit: $90
· Additional: Spent substrate as premium compost

Page 38: Advanced Valorization and Business Models

Advanced Applications:

Application 4: Bio-plastics and Composites

Technology Overview:

SCG as Filler in Bioplastics:

· Matrix Materials: PLA (polylactic acid), starch-based polymers, PHA
· SCG Function: Reinforcement, reduce cost, add natural color
· Loading Levels: 10-30% by weight
· Processing: Extrusion, injection molding, compression molding

Properties of SCG Composites:

· Mechanical: Increased stiffness, reduced ductility
· Thermal: Similar or slightly reduced thermal stability
· Water Absorption: Higher than pure polymer
· Biodegradability: Enhanced due to organic filler

Product Applications:

· Disposable cutlery and containers
· Plant pots (advantage: nutrients released as degrade)
· Packaging materials
· Consumer goods (buttons, decorative items)

Market Considerations:

· Price Premium: 20-50% over conventional plastics
· Target Customers: Eco-conscious brands, green packaging companies
· Challenges: Consistency of SCG properties, processing modifications needed

Application 5: Activated Carbon Production

Process Overview:

1. Carbonization:

· Temperature: 400-600°C
· Atmosphere: Limited oxygen (pyrolysis)
· Yield: 20-30% of dry SCG weight
· Product: Char with preliminary pore structure

2. Activation:

· Physical Activation: Steam or CO₂ at 800-900°C
· Chemical Activation: Impregnation with KOH, ZnCl₂, then heating
· Result: High surface area (500-1500 m²/g)

Properties of SCG Activated Carbon:

· Surface Area: Comparable to commercial activated carbons
· Pore Structure: Mix of micro and mesopores
· Adsorption Capacity: Good for organic pollutants, heavy metals
· Regeneration: Can be thermally regenerated multiple times

Applications:

· Water purification (household, industrial)
· Air filtration (odor removal, VOC capture)
· Food industry (decolorization, purification)
· Medical (antidote for some poisons)

Economic Considerations:

· Production Cost: $2-5/kg (depending on scale)
· Market Price: $10-30/kg
· Competitive Advantage: Lower cost than coal-based activated carbon
· Market Size: Global activated carbon market >$5 billion

Application 6: Animal Feed Supplement

Nutritional Analysis:

· Crude Protein: 10-15% (moderate quality)
· Fiber: 50-60% (mostly insoluble)
· Energy: 15-17 MJ/kg (metabolizable energy)
· Minerals: Good source of potassium, moderate phosphorus

Limitations and Solutions:

· Caffeine Content: May limit inclusion rates
· Solution: Extraction or blending to dilute
· Safe Levels: <0.1% in final feed for most livestock
· Fiber Level: Very high, limits energy density
· Solution: Use as fiber source, not energy source
· Ideal For: Ruminants, horses, rabbits

Processing for Feed:

1. Drying: To <12% moisture
2. Sterilization: Heat treatment to kill pathogens
3. Pelletizing (optional): For easier handling
4. Blending: With other feed ingredients

Inclusion Rates:

· Ruminants: Up to 20% of diet (dry matter basis)
· Poultry: 2-5% (limit due to fiber and caffeine)
· Swine: 5-10% (depending on caffeine removal)
· Fish: Limited use, may affect water quality

Regulatory Considerations:

· Feed Safety: Must meet animal feed regulations
· Caffeine Limits: Vary by country and animal species
· Labeling: Declaration of ingredients and inclusion rates

Application 7: Construction Materials

SCG in Construction Composites:

1. Lightweight Concrete/Bricks:

· Function: Partial replacement of fine aggregate
· Benefits: Reduced density, improved thermal insulation
· Limitations: Reduced strength, increased water absorption
· Applications: Non-load bearing walls, insulation panels

2. Polymer-Mortar Composites:

· SCG as filler in epoxy or polyester mortars
· Benefits: Reduced cost, sustainable material
· Applications: Flooring, repair mortars

3. Sound Absorption Panels:

· Principle: Porous structure absorbs sound
· Processing: Binder + SCG, formed into panels
· Performance: Good mid-frequency absorption
· Applications: Acoustic panels for buildings, studios

Technical Requirements:

· Consistency: Uniform particle size important
· Drying: Essential to prevent mold in final products
· Compatibility Testing: With binders and other materials

Business Models for SCG Valorization:

Model 1: Collection Service Provider

Description: Business collects SCG from generators, processes into stable form, sells to valorization companies
Revenue Streams:

· Collection fees from generators
· Sale of processed SCG to valorizers
· Environmental credits (waste diversion)

Example Structure:

· Service Area: Urban center with 100+ cafés
· Collection: Daily routes with specialized vehicles
· Processing Center: Dewatering, drying, storage
· Customers: Cosmetics companies, mushroom farms, biofuel producers

Economic Example (City of 500,000 people):

· SCG Available: 5 tons/day (est. 1,000 cafés/offices)
· Collection Fee: $0.10/kg ($500/day)
· Processing Cost: $0.05/kg ($250/day)
· Sale Price: $0.20/kg dried ($1,000/day at 50% moisture loss)
· Daily Gross: $1,250
· Daily Net (before overhead): $500
· Annual (250 days): $125,000 net

Model 2: Integrated Valorization Enterprise

Description: Business collects and processes SCG into multiple finished products
Advantage:Higher margins from value-added products
Challenge:Multiple production lines, marketing channels

Example Product Mix:

· Coffee scrubs: 30% of production
· Mushroom substrate: 40%
· Bio-briquettes: 20%
· Other products: 10%

Economic Example (Medium scale: 1 ton SCG/day input):

· Collection: Mostly free (some fees for premium sources)
· Processing Cost: $0.15/kg ($150/day)
· Product Revenue:
· Scrubs: 100kg @ $20/kg = $2,000
· Mushrooms: 400kg substrate → 200kg mushrooms @ $5 = $1,000
· Briquettes: 200kg @ $0.75 = $150
· Total: $3,150/day
· Daily Net: $3,000
· Annual (250 days): $750,000

Model 3: Franchise/Licensing Model

Description: Develop standardized SCG valorization systems, license to local entrepreneurs
Components:

· Technology package (processing equipment)
· Operating manual and training
· Brand and marketing materials
· Ongoing technical support

Advantages:

· Rapid scaling without large capital
· Local entrepreneurs understand market
· Creates distributed processing (reduces transport)

Revenue Streams:

· Franchise/license fees
· Equipment sales
· Royalties on product sales
· Training fees

Model 4: Industrial Symbiosis Park

Description: Co-locate multiple businesses that use each other’s waste streams
Coffee-Focused Example:

· Coffee roaster (produces chaff, defective beans)
· Café cluster (produces SCG)
· SCG processing center
· Mushroom farm (uses SCG substrate)
· Cosmetic company (uses SCG extracts)
· Composting facility (uses all organic residues)

Benefits:

· Reduced transportation costs
· Shared infrastructure
· Collaborative innovation
· Strong sustainability story

Implementation Framework:

Step 1: Source Assessment and Partnership Development

Source Mapping:

1. Inventory: List all potential SCG sources in target area
2. Quantification: Estimate daily/weekly volumes
3. Quality Assessment: Evaluate contamination risks
4. Willingness Assessment: Survey potential partners

Partnership Models:

· Formal Contracts: For large generators (café chains, institutions)
· Informal Agreements: For small cafés, households
· Incentive Programs: Discounts, recognition, shared benefits

Step 2: Technology Selection and Facility Design

Decision Factors:

1. Scale: Small (<100kg/day), Medium (100-1000kg/day), Large (>1000kg/day)
2. Products: Which valorization pathways to pursue
3. Location: Urban vs. rural, proximity to sources and markets
4. Resources: Capital available, technical expertise

Modular Design Approach:

· Start with basic processing (collection, dewatering)
· Add modules as business grows (drying, extraction, etc.)
· Design for flexibility to switch between products

Step 3: Market Development and Product Launch

Market Research:

· Product-Market Fit: Which products have demand in local/export markets?
· Competition Analysis: Existing products, pricing, distribution
· Channel Identification: Retail, wholesale, online, B2B

Pilot Phase:

· Small-scale production (prove concept)
· Test market acceptance
· Gather customer feedback
· Refine products and processes

Launch Strategy:

· Brand Development: Strong sustainability story
· Pricing Strategy: Competitive but premium for green credentials
· Distribution Channels: Multiple channels for risk diversification
· Marketing: Focus on upcycling, circular economy benefits

Step 4: Scaling and Optimization

Growth Pathways:

1. Vertical Integration: Add more processing steps, capture more value
2. Horizontal Expansion: Add more collection routes, new geographic areas
3. Product Diversification: Develop new products from SCG
4. Technology Licensing: Scale through partnerships

Continuous Improvement:

· Process optimization (cost reduction, efficiency)
· Product development (new applications, formulations)
· Market expansion (new customer segments, export markets)
· Sustainability metrics (track waste diversion, carbon savings)

Case Studies:

Case Study 1: “Ground to Ground” – Melbourne, Australia

Model: Community-based SCG collection and composting
Established:2010
Scale:300+ cafés participating, 50+ community gardens

System:

1. Collection: Cafés provide SCG in separate bins
2. Distribution: Volunteers collect and deliver to gardens
3. Use: Composting (mixed with other organic waste)
4. Education: Workshops on composting with SCG

Results:

· Waste Diversion: 500+ tons/year SCG from landfill
· Community Engagement: Strong volunteer network
· Garden Benefits: Improved soil health in community gardens
· Cost: Minimal (volunteer-based, simple infrastructure)

Key Success Factors:

· Strong community ethos
· Simple, replicable model
· Partnerships with local government

Case Study 2: “Kaffeeform” – Berlin, Germany

Model: Designer products from SCG composites
Established:2015
Products:Reusable coffee cups, glasses, accessories

Technology:

· Material: SCG + biopolymers + natural resins
· Process: Molding under heat and pressure
· Properties: Lightweight, durable, dishwasher safe

Business Model:

· Collection: Partner cafés in Berlin
· Production: Local manufacturing
· Sales: Online, design stores, museum shops
· Price Point: Premium (cup: €20-30)

Results:

· Annual Sales: €500,000+ (2021)
· Products Sold: 50,000+ units
· SCG Used: 10+ tons/year
· Awards: Multiple design and sustainability awards

Key Success Factors:

· Strong design aesthetic
· Compelling brand story
· High-quality product performance
· Strategic partnerships

Case Study 3: “Bio-bean” – London, UK

Model: Industrial-scale SCG valorization
Established:2013
Scale:10,000+ tons SCG processed annually

Facilities:

· Processing Plant: 20,000 sq ft in London
· Technology: Proprietary drying and processing
· Products: Coffee logs (for heating), pellets, extracts

Collection Network:

· Partners: Major coffee chains, offices, factories
· Logistics: Optimized collection routes
· Technology: App for scheduling, tracking

Products:

· Coffee Logs: For wood burners, fireplaces
· Pellets: For biomass boilers
· Extracts: For cosmetics, food flavoring

Results:

· Funding: £6+ million in investment
· Customers: Major retailers (Waitrose, B&Q, etc.)
· Awards: Circular Economy Business of the Year
· Impact: Saved 80,000+ tons CO₂ equivalent

Key Success Factors:

· Industrial-scale approach
· Strong technology development
· Strategic partnerships with waste generators
· Multiple product streams

G4T Standards for SCG Valorization:

Minimum Requirements:

1. Collection System: Documented system for SCG collection
2. Basic Utilization: Minimum 50% of available SCG diverted from landfill
3. Product Safety: Basic quality control for any products made
4. Transparency: Records of SCG sources and utilization

Premium Requirements:

1. High-Value Valorization: At least one high-value product from SCG
2. Closed-Loop System: SCG products used within coffee community where possible
3. Innovation: Development of novel SCG applications
4. Market Success: Commercial viability of SCG products demonstrated
5. Community Benefit: Job creation or community engagement through SCG valorization

Practical Exercise: SCG Valorization Business Plan

Participants develop a business plan for SCG valorization:

1. Opportunity Assessment:
   · Map SCG sources in target area (quantity, quality, location)
   · Analyze potential products (technical feasibility, market demand)
   · Assess competition and identify unique value proposition
2. Business Model Design:
   · Choose business model (collection service, integrated, etc.)
   · Design revenue streams and pricing
   · Develop partnership strategy
   · Create brand identity and story
3. Operations Plan:
   · Design collection logistics
   · Specify processing facility and equipment
   · Develop quality control procedures
   · Plan inventory and supply chain management
4. Financial Projections:
   · Startup costs (equipment, facility, working capital)
   · Operating costs (collection, processing, labor, marketing)
   · Revenue projections by product line
   · Cash flow projections
   · Break-even analysis and profitability timeline
5. Implementation Roadmap:
   · Pilot phase (3-6 months): Test collection, processing, market
   · Scale-up phase (6-18 months): Expand collection, increase production
   · Maturity phase (18+ months): Optimize operations, diversify products
   · Key milestones and success metrics
6. Risk Management:
   · Identify key risks (supply, quality, market, regulatory)
   · Develop mitigation strategies for each risk
   · Create contingency plans for major disruptions
   · Insurance and legal considerations

This comprehensive approach to spent coffee grounds valorization demonstrates how what was once considered waste can be transformed into valuable products, creating new business opportunities while addressing environmental challenges and contributing to circular economy goals.

Shall I continue with Pages 39-40 (Coffee Effluent Treatment & Biogas, and Cooperative FCS Collaboration for CE)?