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"DreamRoast" 1kg+ Coffee Roaster
farmroast
Top  #1 Print Post
Posted on 07/25/2007 3:34 PM
1kg.+ electric roaster My goal was a roaster that could do at least 1kg green. with electric convection heat. I mainly wanted the abilities to:
1. control and monitor every function
2 remove the chaff as produced into an external container
3. create a fluidbed action with the beans but achieved mechanically rather than with heated air.
4.dump and cool in a minute or less
5. must roast very evenly
6. ability to add conduction heat when desired
7. ability to imitate various roasters
8. built with durable and dependable components
9. safe to use
farmroast attached the following image:
dr187[292].jpg
Edited by farmroast on 07/31/2007 3:17 PM
 
farmroast
Top  #2 Print Post
Posted on 07/25/2007 3:42 PM
roaster
A) Variable speed convection fan 0-5600rpm
B) High/Low range convection fan toggle
C) Main heater On/Off toggle
D) Beanbats speed control
E) Chaff canister
F) Roasting pot
G) Boost heater control
H) Main heater and fan
I) Tilt dump
J) Bean temp. thermocouple
K) Air temp.
L) Volt/Watt digital display "Kill A Watt" meter
M) Variac 0-140v for main heater
N) Timer
O) PID
P) Cooling drawer- removable cooling tray
Q) Base with Beanbat speed control gearhead motor 0-330rpm
R) Dumping handle in back
farmroast attached the following image:
dreamro272[318].jpg
Edited by farmroast on 07/26/2007 10:56 PM
 
farmroast
Top  #3 Print Post
Posted on 07/25/2007 3:51 PM
The Beanbats bat the beans into a whirl up the sides of the pot. the rpm is adjustable from 0-330 rpm. I general run it in the 200-300 range, small batch 1/2lb or less will use 100-200rpm I can unscrew the top bolt and am playing with trying different size and shaped bats. The roasting pot is a cut down stainless Steel stock pot. and was recycled from my BreadMachine/Turbo oven roaster.
farmroast attached the following image:
dreamro384[294].jpg
Edited by farmroast on 07/30/2007 11:19 PM
 
farmroast
Top  #4 Print Post
Posted on 07/25/2007 3:57 PM
Sewing machine motor replaced the slower speed(2000rpm) motor that was in the turbo oven top. 0-5600 rpm sewing motor also has a high and low speed range that is adjusted with the rheostat and toggle on the front of the top.
farmroast attached the following image:
dreamro467[295].jpg
Edited by farmroast on 07/31/2007 3:27 PM
 
farmroast
Top  #5 Print Post
Posted on 07/25/2007 4:02 PM
Base
2 aluminum plate cut to 12" diameter with a cutoff front face. Drilled and tapped uprights. Angle iron motor mounts. Motor is a 25watt ac variable speed gearhead 5:1 with separate control box and potentiometer. The orange stuff is high temp silicon that I used as a gasket between the frame and the skin. Cut and bent a fan out of a copper scrap.
farmroast attached the following image:
dreamro583[296].jpg
Edited by farmroast on 07/30/2007 11:11 PM
 
farmroast
Top  #6 Print Post
Posted on 07/25/2007 4:08 PM
Boost-large batch heater. Just peeled the heater with its conduction plate and controller off the bottom of an electric fry pan. Its sandwiched with spacers between the top plate of the base and right below the roasting pot. I use it to balance the heat for a normal size batch or can use it as a boost for larger batches. Or can use it with slow beanbat speed to imitate a conduction roast.
farmroast attached the following image:
dreamro684[297].jpg
Edited by farmroast on 07/25/2007 8:43 PM
 
farmroast
Top  #7 Print Post
Posted on 07/25/2007 4:12 PM
Top thermocouple does air temp just before it hits beans (air flow circles down the sides of the pot and returns up in the center). Lower thermocouple measures bean temp. The S shaped slot is where the chaff exits into the external chaff canister( yes its hard to believe that 99% of the chaff of even a dry processed will exit through the small slot but it does)
farmroast attached the following image:
dreamro765[298].jpg
Edited by farmroast on 07/25/2007 6:54 PM
 
farmroast
Top  #8 Print Post
Posted on 07/25/2007 4:16 PM
To keep stuff from getting into the stock turbo oven heater cover I added some ss screen and just drilled and riveted to the original cover.
farmroast attached the following image:
dreamro881[299].jpg
Edited by farmroast on 07/25/2007 6:57 PM
 
farmroast
Top  #9 Print Post
Posted on 07/25/2007 4:21 PM
Cooling drawer with pine and ss screen bean tray insert. Fan sucks air through beans cools in less than a minute. Pull drawer out to dump roast, slide in to cool, remove tray to pour cooled beans.
farmroast attached the following image:
dreamro984[300].jpg
Edited by farmroast on 07/25/2007 7:02 PM
 
farmroast
Top  #10 Print Post
Posted on 07/25/2007 4:26 PM
whirling beans
With the high speed beanbats the beans stay suspended in the pot.
farmroast attached the following image:
dreamro1081[301].jpg
Edited by farmroast on 07/25/2007 7:04 PM
 
farmroast
Top  #11 Print Post
Posted on 07/25/2007 4:41 PM
bean temp, air temp, on top of variac (to right)is a "kill A Watt" meter reads volts, watts etc. output to main heater.
farmroast attached the following image:
dreamro1182[302].jpg
Edited by farmroast on 07/25/2007 7:08 PM
 
farmroast
Top  #12 Print Post
Posted on 07/25/2007 4:43 PM
Lift off top then grab handle in back and pivot dump (sorry couldn't take action shot, no assistant) 2 angle brackets are bolted under cart top with a piece of 3/8 threaded rod through the front of the roaster base and frame.
farmroast attached the following image:
dreamro1385[303].jpg
Edited by farmroast on 07/25/2007 10:36 PM
 
farmroast
Top  #13 Print Post
Posted on 07/25/2007 4:44 PM
chaff canister
farmroast attached the following image:
dreamro1282[304].jpg
 
farmroast
Top  #14 Print Post
Posted on 07/25/2007 4:46 PM
1kilo estate run Costa Rica green 16min full city+
Roaster is pre-heated to 350-400, endless roast profile possibilities and adjustability.First crack can easily be obtained in less than 10mins if desired . conduction(lower element) and convection(upper element) both blendable and adjustable. When finished the top is lifted and the batch is dumped by lifting handle on back of roaster and tilting(see pic) into cooling drawer with fan. When cool, lift tray out.
farmroast attached the following image:
dreamro1594[305].jpg
Edited by farmroast on 07/31/2007 5:06 PM
 
farmroast
Top  #15 Print Post
Posted on 07/25/2007 4:55 PM
Variable speed convection fan rheostat , high-low range fan toggle (upper right), main heater on/off toggle (lower right)
Costs to build:
Thanks to the Salvation army store, tag sales, flea market, my friends metal shop scrap heap, ebay, craigslist etc. for keeping costs down.
prices include shipping.
used galloping gourmet turbo oven top (craigslist) $25.
Oriental motors(industrial) AC 25w speed control motor, speed controller,potentiometer (ebay, new surplus) $35.
sewing machine motor (flea market) $5.
cooling fan (salvation army store) $8.
Staco 22amp variac used (ebay) $114. shipped
2TIF 7000 thermocouples new surplus (ebay) $30.each
Kill A Watt meter new (ebay)$23.
PID W/timer and case used (ebay) bought a lot of 3 for $18. each
convection fan rheostat new (ebay) $14.
microwave cart new (target) $34.
pine board for cooling box and tray (lumber yard) $10.
ss stock pot 12" diameter used like new(got at flea market few years back)$? cant remember but probably less than $15
ss skin for base used trash can with broken top flipper (tag sale) $5.
CO top skin flour canister and strainer (salvation army) $6.
electric fry pan w/heater,still use fry pan! (flea market) $17.
toggle switches new (hardware store) $10
8" angle brackets and rod for tilt dumping (hardware store) $12
ss screen(over-sink strainer) for cooling tray new(tj max) clearance $12
metal for base and drive shaft(friends metal shop scrap parts heap)$20
assorted nuts and bolts,screws, sabre saw blades, (had some bought some) $? Tools: Electric hand Jig/sabre saw,elec. drill. grinding wheel. chopsaw. couple taps, reg. assorted hand tools.
farmroast attached the following image:
dreamro1683[306].jpg
Edited by farmroast on 07/31/2007 5:11 PM
 
Dan
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Posted on 07/25/2007 5:19 PM
Nicely done! Thanks for the entry.
 
Web
EddieDove
Top  #17 Print Post
Posted on 07/25/2007 8:43 PM
Great work! Thanks, Ed.
Respectfully,

Eddie Dove

The South Coast Coffee Roaster
vita non est vivere sed valere vita est
Home Coffee Roasting Blog and Reference
http://southcoast...gspot.com/
 
Web
David
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Posted on 07/25/2007 10:00 PM
Nice presentation of your information.
 
Mike
Top  #19 Print Post
Posted on 07/26/2007 1:14 AM
Really nice work. And it looks like there was a lot of it (work that is). A KiloGram is a nice size.

Mike
B)
 
ronnieb
Top  #20 Print Post
Posted on 07/26/2007 6:18 AM
I'll just say we're all jealous. s:2 Very nice job. Do you use 2 circuits to run everything?
Edited by ronnieb on 07/26/2007 6:19 AM
 
seedlings
Top  #21 Print Post
Posted on 07/26/2007 9:28 AM
VERY nice roaster! A little intimidating at first glance, but once I read through... sweet & tasty. It looks like you roast indoors... how much smoke do you get? I noticed you said you took that Costa Rican to 1C. If you usually stop at the lighter roasts, I suppose smoke really isn't an issue.

I like the dump mechanism. That's great. Do you have a nice way to get the roasted beans out of that lovely screen tray?

Just amazing. What the heck are we all doing here on-line? We should be transfoming the roasting industry...




maybe we are


CHAD
 
farmroast
Top  #22 Print Post
Posted on 07/26/2007 9:38 AM

Quote

seedlings wrote:
VERY nice roaster! A little intimidating at first glance, but once I read through... sweet & tasty. It looks like you roast indoors... how much smoke do you get? I noticed you said you took that Costa Rican to 1C. If you usually stop at the lighter roasts, I suppose smoke really isn't an issue.

I like the dump mechanism. That's great. Do you have a nice way to get the roasted beans out of that lovely screen tray?

Just amazing. What the heck are we all doing here on-line? We should be transfoming the roasting industry...




maybe we are


CHAD
I roast inside and outside depending on weather. Have a small room with exhaust fan in window. The screen tray is just pulled out to empty.
 
seedlings
Top  #23 Print Post
Posted on 07/26/2007 9:47 AM
I just re-read the entire thread. I love it.

Can you hear the cracks ok?

CHAD
Edited by seedlings on 07/26/2007 9:55 AM
 
ginny
Top  #24 Print Post
Posted on 07/26/2007 10:48 AM
WOW,

Dream Roast is right, way, way cool work. Clean, tight and looks great. Do I get a 1/2 pound of fresh dream roast if my vote swings your way??

ginny

s:8s:8s:8s:8s:8
 
farmroast
Top  #25 Print Post
Posted on 07/26/2007 11:15 AM

Quote

ginny wrote:
WOW,

Dream Roast is right, way, way cool work. Clean, tight and looks great. Do I get a 1/2 pound of fresh dream roast if my vote swings your way??

ginny

s:8s:8s:8s:8s:8
Thanks ginny, guess I'd have to pm you on that request!s:8
 
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