As a forward-thinking export house specializing in premium South Indian coffee, Achrekar Merchants is committed to innovation and excellence, investing in state-of-the-art processing technology to establish Tamil Nadu as a global hub for Speciality Degree Coffee. Our commitment to integrating advanced technology with time-honored tradition remains relentless and consistent.
With a sprawling infrastructure of 5+ specialized units covering over 75,000 sq. ft., our facility is equipped with cutting-edge precision roasting, heritage grinding, and aroma-lock packaging technology, boasting an impressive annual capacity of over 50,000 mts. Managed by a team of industry veterans and certified coffee professionals, we ensure seamless operations and export-grade consistency for every batch.
Our automated systems are designed to minimize human intervention, preserving the delicate sensory profile of every bean while maintaining uncompromised quality at every vital checkpoint. Beyond technology, we prioritize the safety and well-being of our team, ensuring a workspace that meets the highest health and ethical standards. This dedication to excellence has solidified our standing as a benchmark for Responsible Sourcing and a Sustainable & Ethical Coffee Supply Chain.
Here is the updated Green Coffee Cleaning & Grading content, structured into two professional paragraphs:
Our green coffee cleaning and grading line was established to set the benchmark for premium export-quality coffee, and it has been consistently upgraded to keep pace with the latest global advancements in speciality coffee processing. By leveraging state-of-the-art technology, we meticulously separate coffee beans based on their physical profile including size, density, and color ensuring that only the most uniform and superior quality beans qualify for our speciality range. This precise grading process is fundamental to achieving the consistent roast development and nuanced flavor profile that our international clients expect from authentic South Indian coffee.
The facility is engineered to remove farm-level admixtures, defect beans, and contaminants through a series of advanced stages, utilizing high-precision equipment such as Sifters, De-Stoners, Gravity Separators, Multivision Sortex, and On-line Metal Detectors. This comprehensive cleaning system effectively eliminates unwanted debris and inferior beans that could compromise the sensory quality or safety of the final product. With rigorous quality controls integrated directly onto the shop floor, we manage the identification and segregation of rejected material with absolute accuracy, ensuring that every shipment of our Peaberry, Arabica, or Robusta beans meets the most stringent purity and safety protocols of global markets.
Our facility is equipped with high-capacity grinding lines capable of processing over 3,000 tons of coffee per annum, specifically tailored to meet the diverse grind requirements of global roasters and distributors. Before entering the grinding stage, the beans undergo a multi-stage refinement process where specialized zig-zag classifiers are utilized to remove any remaining heavy admixtures or stones based on density differences, ensuring a high-purity final product.
By integrating advanced Sortex technology, we have the capability to remove any discolored or fungal-prone beans during the pre-processing phase, guaranteeing that only the finest quality coffee enters our mills. The online installation of magnets and precision sifters with varying screen sizes allows us to offer a wide range of custom grind profiles from coarse textures for cold brew to finely milled powder for traditional South Indian filter coffee ensuring every batch is optimized for the intended brewing extraction and aesthetic appeal.
The installation of our advanced coffee milling lines is designed to minimize human intervention through the use of high-tech PLC Controllers, ensuring absolute consistency in every batch. During the milling process, temperature deltas are critically monitored and controlled to prevent overheating; this is vital for preserving the coffee’s delicate volatile oils and complex flavor profiles that characterize our speciality blends. At Achrekar Merchants, we have established three dedicated milling lines with increasing capacities to cater specifically to the varying textures and volumes required for our whole bean trade, peaberry selections, and premium ground coffee powders.
With an annual capacity of 3,000 mts, this line is engineered to process high-density, high-altitude coffee beans such as premium Arabica and Peaberry. These beans are milled to precise mesh sizes in a single pass to maintain uniform particle distribution. Processing temperatures are strictly monitored throughout to prevent any heat-induced loss of volatile oils, ensuring the flavor profile of the origin is fully preserved. Every batch is preceded by meticulous hand-sorting to ensure only stone-free, pure beans enter the mill, followed by an end-of-line blending process for perfect homogenization of our speciality selections.
Fulfilling an annual capacity of 5,000 mts, Milling Line 2 is dedicated to our high-volume speciality coffee blends. This line features a specialized mechanical cleaning system utilizing sifting, air classification, and final hand-sorting to ensure absolute bean purity post-roast. To lock in the fresh-roasted aroma, the ground coffee is homogenized in water-chilled blenders, ensuring it reaches the packaging stage at room temperature. The final product is packed in a dedicated clean room with high-efficiency airflows, maintaining a sterile and safe environment for both the product and our professionals.
Known as the “Premium Mill Project,” this is one of our most advanced facilities, featuring a production capacity of over 1,800 kgs per hour and an annual capacity of approximately 15,000 mts. A dedicated 8-ton silo ensures a constant feed directly from our industrial roasters. The intake hoppers are mounted on load cells, allowing us to replicate complex recipes (such as our signature 90/10 and 80/20 Degree Coffee blends) with exact precision every time. Utilizing two parallel water-chilled blenders, we ensure rapid cooling and consistent mixing before the product is automatically packed into export-ready bags ranging from 25 Kgs to 1000 Kgs.
No authentic South Indian coffee experience is complete without the perfect Degree Roast. We operate a dedicated industrial roasting line with an annual capacity of 4,000 mts, specifically designed to achieve the precise “Degree Coffee” profiles that our brand is known for. These specialized roasters are ideal for crafting custom-roasted blends, ensuring that we deliver the exact flavor intensity and deep aroma desired by international markets. We recognize that the precise degree of roasting is the most critical factor in unlocking the unique character and complex fragrance of every coffee bean in our collection.
Our specialized Coffee R&D and Sensory Lab is responsible for developing signature roast profiles and meeting the specific flavour requirements of our global partners. The team conducts meticulous sensory trials and trial roasts to perfectly match cupping samples provided by customers, ensuring that every custom blend meets the exact aroma, body, and acidity markers requested for their market.
Steam Sterilization is an environmentally friendly and highly effective method for ensuring the microbial safety of coffee beans without compromising their sensory profile. This process yields zero chemical waste while allowing for precise monitoring of critical parameters such as moisture, temperature, and exposure time. Our advanced sterilization system for coffee integrates a seamless flow between validated continuous and batch systems to achieve a 5-log reduction in microbial load, ensuring our products meet the strictest food safety regulations of international markets.
