Translating Sample Roaster Profiles (1 kg) to Commercial Production (15–30 kg)

How to scale a winning 1 kg cupping profile from the RC ALP-1 onto a 15 kg CAST-15 or 30 kg CAST-30 without losing flavor clarity or acidity balance.

The Scaling Trap: Why Times and Temperatures Never Match 1:1

Sample roasters (like the RC ALP-1) and commercial production roasters (like the CAST-15 or CAST-30) have completely different surface-area-to-volume ratios and thermal masses. If you copy a 9-minute curve directly from a 1 kg sample roaster onto a 15 kg machine, the production batch will inevitably suffer from underdeveloped bean cores or scorched outer faces.

Core Scaling Principles

1. Match Key Thermodynamic Landmarks (Not Heat Settings): - Match the Yellowing Phase Percentage (typically 42%–48% of total roast duration). - Match the Maillard Duration to ensure equivalent carbohydrate caramelization. - Match the Development Time Ratio (DTR) within ±0.5%.

2. Compensate for Thermal Inertia: - A 15 kg machine contains 180 kg of cast iron and carbon steel mass. It cannot decelerate heat as rapidly as a sample roaster. - Make burner downward modulations 45 to 60 seconds earlier on the commercial roaster than on the sample unit.

3. Color & Density Target Verification: - Always verify profile transfer using an Agtron color spectrophotometer (measuring both whole-bean and ground color spreads) and roasted bean bulk density. A ground-versus-whole spread under 15 Agtron points confirms thorough inner core solubility.

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