Straight from the Farm

Due to the substantial amount of blended coffee PrairieFire sells, we acquire multiple varieties of by the truckload (37,500 pounds). All green coffee beans come in burlap bags weighing up to 150 lbs. per bag based on the coffee producer. Depending on overall demand, our specialty coffees are purchased in quantities ranging from 2 to 10 bags.

Creating Private Blends

The green coffee beans are emptied into a special bin which conveys the raw beans to a shaker and cleaner removing any foreign debris. Subsequently, the green coffee beans are conveyed to a storage container above the roaster where they await the next step in their journey. 

Entering The Roaster

The roasting process is initiated by activating the inner drum of the roaster. The green coffee beans are then introduced into the roaster where the rotating drum mixes the coffee beans to specification, creating a blend.

Flame Roasting

Once the green coffee beans are in the roaster, the gas valve is opened and the flame is automatically ignited. The Roast Master adjusts the airflow to ensure the roaster operates at the proper heat capacity. It is crucial for the Roast Master to anticipate various conditions which may affect the quality of the final product.  

Almost There!

The roasting duration typically spans 15 to 20 minutes, subject to factors like ambient temperature, air flow, moisture content of the coffee beans, and the type of roast (light roast, dark roast, espresso, etc.).

Quality Assurance

A small sample of the coffee beans are taken and their color is compared against a standard roast profile following the flame roasting process. After the flame goes out, a slight mist of water is sprayed over the roasted beans to eliminate any cinders. The inner drum continues to rotate the coffee beans until they cool.

Cooling

Post-flame roasting, the coffee beans are transferred to a cooling bin with a stirring mechanism in the middle. The bin's flat bottom, riddled with small holes, allows a powerful fan to draw air down through the coffee beans for effective cooling. Once cooled, the roasted coffee beans are placed in large bins above the grinders to degas overnight before grinding.

Packaging

After roasting, specialty origin coffee is ground to precise specifications and packaged. An automated packaging machine measures the exact amount of coffee for each package, forms the packaging film, and then fills and seals each bag. This equipment can produce approximately 50 coffee bundles per minute. Once complete, we ship and deliver to our customers' doorstep!