Engineering The Perfect Cup Of Coffee

Consumer Product Design
 

Before they joined Acorn Product Development, our team members were already experts in their fields, helping companies bring innovative solutions to life. Now, that same energy and engineering prowess fuels everything we do at Acorn. One standout project involved perfecting a key part of your morning routine: crafting the perfect cup of coffee.

One member of our team worked extensively on this high-performance coffee roaster, solving challenges that go far beyond simply heating beans. Their work highlights the engineering expertise that we harness on our cross-functional team at Acorn.

 

 
 
engineering services
food and beverage equipment
 

The Challenge: Transforming Coffee Bean Roasting Into a Precise Engineering Masterpiece

Designing food and Beverage equipment is as much science as it is craft. This particular project required designing a roaster that could consistently handle 1.5 lbs of beans per batch and deliver optimal roasting results within 9-14 minutes. But beyond timing and flavor, the machine also needed to comply with strict NSF and UL certifications, which guarantee safety and quality.

Every detail mattered: The precise control of temperature vs time was crucial in enhancing the coffee's flavor profile. Therefore, complex engineering solutions were implemented to give superior control. Not only did they optimize energy efficiency through heat management, they also included features such as an easy chaff removal system to streamline operations.

The roaster was designed to operate without external venting, thanks to a catalytic converter that allowed ductless installation by neutralizing harmful compounds. A built-in heat exchanger further increased energy efficiency and kept exhaust temperatures within safe limits.

Engineering Expertise Air Flow Diagram
 

The Solution: Advanced Engineering on Every Front

At Acorn, our employees thrive on challenges like this one. During this project, they demonstrated a suite of specialized engineering capabilities that spanned multiple disciplines:

 

1. Thermal and Airflow Engineering

Services: Heat management and transfer analysis, thermal simulations, airflow, and cooling system design. 

Tools: Computational Fluid Dynamics (CFD) software (e.g., ANSYS, COMSOL) for analyzing heat, airflow, and temperature control. Finite Element Analysis (FEA) for thermal design and analysis.

2. Mechanical Engineering

Services: Structural design, enclosure design, electromechanical packaging, material selection, cabling and mechanism development. Also, design for assembly and manufacturing and BOM development.

Tools: CAD software (e.g., SolidWorks) for detailed part and assembly design. Finite Element Analysis (FEA) for stress analysis and design optimization.

3. Electromechanical Engineering

Services: Design of motorized components and actuators to control electromechanical parts like the bean inlet and outlet doors, and  cabling design   

4. Electrical Engineering

Services: Electrical system and custom PCB design, sensor integration for temperature control, power management, and system wiring.

Tools: Electrical design software (e.g., Altium and Visio ) for PCB design, circuit schematics, and wiring layouts.

5. Software Engineering

Services: Embedded software development for controlling the roasting cycle, monitoring roast profile, and adjusting parameters.  monitoring safety aspects, and transfer of information to the cloud

Tools: Embedded development environments, real-time operating systems (RTOS), and custom firmware development.

6. System Engineering

Services: Integration of all components—thermal, mechanical, electrical, and software—to ensure proper system functionality and compliance with regulatory standards (NSF, UL).

7. Regulatory Compliance

Services: Ensuring compliance with NSF, UL, and other safety standards.

Tools: Certification and compliance software for tracking and validating regulatory standards.

 

By using these services and tools, the design and development process can meet performance, safety, and regulatory requirements efficiently.

 

 

 

The Impact: More Than Just Great Coffee, It’s Engineering Excellence

Changing how the world enjoys coffee is just one example of how Acorn’s multidisciplinary engineering services come together to create something exceptional. From concept to compliance, our team delivers solutions that perform reliably and efficiently.

Do you have an engineering challenge that requires expertise across multiple disciplines? Whether you're aiming to revolutionize an everyday experience or tackling a more complex industrial problem, Acorn Product Development is here to help. Our team’s depth of knowledge spans engineering and user-centered design, offering you complete product development services in one place.

No matter what stage you are in the product development process, contact us today for a free consultation. Take the first step toward turning your product idea into reality!

 
Jacob McMullen