DETAILED PRODUCTION FLOW WI-443-001-D

DETAILED PRODUCTION FLOW

1. Green Coffee Purchasing
a) Prior to green coffee being purchased and received into our plant it will have
been tested per our quality control procedures and the supplier must be listed
on the Approved Supplier Register.
b) The Accounting Department places a purchase order to the appropriate vendor.
All purchase orders pull from coffees previously contracted with the vendor and
contain the appropriate quantity, lot marks and country of origin.
2. Green Coffee Receipt
a) Green coffee arrives at our facility and the receiving party verifies that the green
coffee is per the specifications outlined on our purchase orders. The Logistics
Manager confirms that the quantity, bag marks and country of origin are as
specified on the purchase order and documents the findings on the Receiving
Reports.
b) The Logistics Manager conducts a random quality check of 5 bags of every
incoming 25 bag pallet. These quality checks are to ensure the beans received
match the beans originally contracted (samples are located in the QC lab).
c) Once the P.O. is confirmed the green coffee is placed on raised pallets in the
designated storage area. (Refer to the Stock Rotation Program for storage
requirements.)
i. Organic coffees received are tagged as such and isolated from regular
coffees upon storage.
3. General Receipt
a) All carrier trucks are inspected prior to unloading. Packaging material is checked
to our quality standards, tagged with the date of receipt and stored in the
designated area. (Refer to the Procedures for Shipping & Receiving Work
Instruction.)
4. Roasting
a) The Production Manager outlines the daily roasting schedule on the Roasting
Logs.
b) The Roasting Logs are created by referring to the Finished Product
Characteristics Form which outlines each customers product specifications.
i. Organic coffees are entered into the log and highlighted in non-yellow
ink to differentiate from regular coffees.
c) The Master Roaster pulls green coffee per the blend specifications of each item
on the daily roasting schedule.
d) The Master Roaster has Quality Control samples of each roasted whole bean
coffee. He continually checks the coffee beans during roasting to ensure that
the roasted coffee will meet the necessary color specifications.
e) Green coffee is passed through a screen to remove any large foreign particles
before entering the roaster.
f) Roasting commences and continues until the color and texture of the roasted
coffee reaches the proper specifications outlined in the customers QC sample.
g) Coffee is then quenched with filtered water to stop the roasting and the coffee
is moved to a cooling cart.

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 DETAILED PRODUCTION FLOW WI-443-001-D

h) Coffee that is in the cooling cart is then entered in the Roasting Logs which
outlines the blend, lot number, temperature and the customer that will receive
the end product. Roasting Logs are retained for 5 years.

5. Whole Bean Coffee

a) The whole bean coffee is moved via vacuum process through a magnetized
conveying system removing any metal particles before either entering a super
sack or the appropriate storage bin.
b) Whole bean coffee that is moved to a super sack will either be shipped to
customers on a pallet or continue through production to the degassing area.
i. Super Sacks are designated and tagged for each coffee type so no cross-
contamination occurs between decaf, organic, flavors, etc.
c) Super Sacks are tied shut, labeled with description and roasting date, and
moved to the designated degassing/holding area.
6. Flavors added to Whole Beans
a) If flavors are to be added to the coffee it is done at the whole bean stage after
the degassing is completed. The whole beans are moved to mixers where the
appropriate amount of flavoring is mixed in and recorded on the Mixing Logs.
b) The flavored whole beans are then moved to the coffee grinder designated for
coffees with additives.
c) The ground coffee is moved into a Super Sack that is appropriately before being
moved to the packaging stage.
7. Ground Coffee
a) Coffee to be ground is moved to one of two storage bins that are connected to
grinders.
b) Quality Control Grind Samples are pulled so that the grinders can be set to the
appropriate grind settings.
c) Coffee is moved up magnetized elevators to the grinders and the grind is
periodically checked to verify that the QC target is being maintained.
d) Ground coffee is sifted before leaving the grinders and is either moved to one of
three storage bins that are connected to packaging machines or moved to Super
Sacks.
e) Ground coffee that is moved to a Super Sack will either be shipped to customers
on a pallet or moved to another part of the plant for degassing.
f) Super Sacks are tied shut and moved to the degassing area.
g) Before grinding organic coffees, the equipment is purged by running 5 pounds
of organic coffee through the grinder, which will be disposed of. This ensures
no cross-contamination. (All purging activity is documented on the Purging
Logs.)
8. Additives in Ground Coffee
a) Occasionally customers request an additive to be mixed into ground coffee. The
customer supplies the appropriate amount of additives to be blended with 200
pounds of coffee. The additives are stored in the second floor additives room
until their time of use. (All mixing is documented on the Mixing Logs.)
b) The mixer is cleaned by a two step process. First the mixer is blown out with a
high pressure air house, then 5 pounds of the next blend of coffee is run
through the mixer to purge the system. Those 5 pounds of coffee are disposed

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 DETAILED PRODUCTION FLOW WI-443-001-D

of after purging the system. (All purging activity is documented on the Purging
Logs.)
i. Organic additives are treated in the same process.
c) After purging, the coffee is moved to Super Sacks that are designated for coffee
with that specific additive.
9. Packaging
a) The coffee, whether ground, flavored or whole bean will be moved to the
appropriate packaging station.
b) The packaging equipment will be loaded with the corresponding packaging
material.
c) Coffee is fed via a feed system or super sack to the appropriate machine.
i. Purging is conducted before packaging organic coffee by running 5 lbs of
the corresponding blend through the packaging machines.
d) The sealed bags are loaded into boxes in the quantity specified on the order
form. Each box is labeled with the customer name, quantity, bag size,
production date and item I.D. number, where applicable. (Specific labeling
instructions are outlined in the Finished Product Characteristics.)
e) Each operator takes note of the coffees roast date and the date of receipt of
the packaging material. These dates are used for tracking purposes.
f) Boxes are sealed and placed on pallets to be moved to the distribution center.
g) All packaging is documented on the Production Logs.
h) The equipment is dry-cleaned by an air compressor between each use.
i) Equipment is purged after coffee with additives and organic coffees are
packaged. (All purging activity is recorded on the Purging Logs.)
i) Between packaging of organic coffees, the equipment is purged by running
5 pounds of the corresponding organic coffee through the equipment,
which will be disposed of. This ensures no cross-contamination.
10. Distribution
a) Every Purchase Order details distribution information and is verified by the
Logistics Manager or Shipping/Receiving Manager.
b) Finished product on pallets is loaded onto approved carriers or is shipped in
cases via Federal Express. All carrier trucks are inspected prior to loading.
c) Every shipment is verified for completion and quality by the Logistics
Manager/SQF Practitioner prior to shipping.
d) Where applicable, product lot codes consisting of roast date and packaging
material receipt will be detailed on the shipping documentation.

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