The production cycle
Since 1997, the whole Caffè Mauro's production cycle takes place in the wide industrial plant of Villa San Giovanni, right outside Reggio Calabria. The factory takes up a 35,000 square meters surface and is considered one of the most modern production plants in Europe.
The vibrating sieves, through different stages, eliminate possible impurities and foreign bodies. In the first stage light bodies, such as twigs, leaves and little sticks are removed from the coffee. Then, the heavy bodies are removed. The following stage - the storage - is carried out in silos with a total capacity of about 700,000 kg.
Roasting is the most delicate stage of the coffee production cycle. For this reason the company developed a sophisticated technology that, through a strict control of cold and hot air flows, ensures the perfect cooking of the bean and brings out its specific organoleptic characteristics. The different kinds of green coffee are roasted separately. Caffè Mauro can count on three roasting lines which follow a slow roasting cycle, with a production capacity of 21,000 kg per turn. Compared to the traditional fast or semi-fast industrial cycles, Caffè Mauro devotes much longer times to roasting: from 15 to 18 minutes. The aim is bringing out the aromatic potential of each kind of coffee. The roasted coffee is then cooled down by air in a special basin with rotating blades and weighed to verify the weight loss, which can vary, depending on the bean origin, from 17% to 20% of the initial weight. The roasted coffee undergoes another sorting, in order to eliminate those foreign bodies that due to their different specific weight were not eliminated in the previous stage of sorting and cleaning. The coffee is then moved through a closed circuit to the roasted coffee silos, where it remains for a certain period of time to mature and degas. After that, the coffee is ready to be blended or ground. The grinding occurs through a device able to control the particle size standards provided for each specific line of product. The compliance with these parameters becomes essential to ensure the best result in the final consumer's cup, both for espressos and for mochas. The particular slow roasting method considerably contributes to Caffè Mauro's quality. Focusing all its attention on the most delicate moment of the processing cycle of the bean, Caffè Mauro ensures the quality, the aroma and the taste of a good espresso. During the roasting, the so-called "Maillard reaction" occurs: the bean loses weight, changes colour, gets more volume and develops the aromas. Unlike many companies that use an industrial method with 5-6 minutes cycles at high temperature, Caffè Mauro uses a slow method, with cycles of 15-18 minutes. Moreover, at the end of the cycle, before starting the preparation of the blends, the roasting is stopped and the beans are cooled with air to avoid the risk of an excessive roasting. That's why Caffè Mauro's taste is so special: we have decided to focus completely on those precious minutes to ensure the maximum preservation of the organoleptic properties of the coffee beans and to respect therefore the natural roasting times. The water contained in the raw beans evaporates gradually, without causing the damaging "popcorn effect". The sugars caramelize without burning, ensuring the absence of a bitter aftertaste. The precious essential oils, which define the fragrance and aroma of the blend, are intensified. The bean is evenly cooked as far as the core. The slow roasting ensures, the blend being equal, a greater quality result. For this reason Caffè Mauro's slogan, thought to better enhance its particular roasting method, is "se aspetti c'è più gusto" ("If you wait, it's more tasteful").
Caffè Mauro's factory is equipped with nine packaging lines, depending on whether it's whole bean coffee, ground coffee, capsules or pods. A line is reserved for 1kg and 500g packs. Then there are two lines for 250g packs, in single or multipack formats. Furthermore, there are two espresso pod lines, two espresso capsules lines and another one dedicated to selected families, which produces 3kg cans of whole bean coffee and 250g cans of ground coffee. Moreover, there is a line with two presses which produces the empty capsules. The equipment is flexible and completely computerized. In order to preserve the product in the best way possible, the lines blow nitrogen, remove the air from the packs and check the weight of every single pack. Non-compliant packs are automatically discarded.