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The factory

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THE FACTORY
Production
The Lavazza production cycle is divided into different stages; selection of the green coffee, its arrival in the Lavazza plant, laboratory tasting, storage of the green coffee, air roasting, blend composition, grinding and packaging and the warehouse.

Storage of the green coffee
The Lavazza factory includes two storage towers with 134 silos containing different varieties of coffee. Storage capacity is 5,000 tons. The green coffee is loaded automatically through bag-cutters or tanks and is then sorted to remove powder, stones or other foreign matter.

Laboratory tasting
Lavazza's team of tasters is made up of professionals who taste both roasted coffee and green coffee upon its arrival at the factory every day.

Air roasting
This is the phase in which the coffee is transformed, because this is when the characteristic aroma and flavour of the coffee develop. The roasting cycle (duration and temperature) varies according to coffee variety and blend. Roasting takes place in machines that use high-temperature air to heat up the coffee, which literally "floats" in the stream of hot air. The beans lose 16-22 per cent of their weight.

Composition
The cycle of blend composition and roasting is highly automated and is managed by a central data processor that controls all the activities in the plant.

Packaging
Coffee packaging after roasting is done according to the final characteristics of the product.
  • Ground products in flexible packets or cans.
  • Ground products in pods.
  • Whole-bean products.
After roasting, the product is treated again to remove bits of coffee. Finally, it is vacuum-packed in bags with one-way valves. The line consists of packaging machines, cartoning machines and palletizers.

Logistics
Lavazza directly manages product distribution and uses its own warehouses as well as warehouses on a contract basis. In Italy, Lavazza's logistics poles are in Turin, Milan and Rome. The logistics pole in Turin carries out both distribution and procurement for the other logistics centres in Italy and abroad. Therefore, it is equipped with an automated computerised warehouse with an overall storage capacity of 11,000 slots for two-meter-high pallets. Handling is managed by a central data processor using an unmanned roller and four transelevators.

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