It’s hard to imagine life without coffee. If you’re one of the 2.5 billion people who drank a cup of coffee today, then you have Brazil to thank for that caffeine fix.
Brazil is responsible for about a third of the world’s total coffee production. Plantations in the country span six regions, across different climates. Diverse temperatures yield a variety of flavors, which satiate many discerning palates around the world.
In the city of Paraná, Cornélio Procópio — stands the Iguaçu manufacturing plant, which churns out more than 20,000 tons of coffee products a year, equivalent to around 10 billion cups of coffee. 75% of their products are shipped to supply companies in 50 countries, all made to their specific needs: be it freeze-dried, spray-dried, agglomerates (in powder form), or as extracts. Iguaçu was founded in 1967 by local farmers. In 1972, the Japanese company Marubeni acquired a 35 percent share of the company's capital, and a 100 percent share in 2014.
The perfect cup of coffee isn’t created when ordered from a barista… or even overnight. It starts with the inspection of green coffee beans, which are examined for moisture content, defects, a food contaminant and of course the flavor. A coffee tasting, called “cupping”, is done to ensure that the beans meet the specifications. Only then are the beans roasted, coarsely ground, and sent through an extraction machine. This is followed by a second “cupping” session, before the concentrated liquid is converted into coffee crystals using low (freeze-dried) or high temperatures (spray-dried.)
Iguaçu is also one of few companies that are capable of freeze-concentrating. One of the problems of instant coffee producers is maintaining that “freshly brewed” scent in every cup. Freeze-concentrating conserves much of that rich aroma. For these orders, the company ships in freezer containers, in order to maintain the integrity of the product.
“Marubeni brought more advanced technology from Japan, which reinforced [our] manufacturing capacity,” says Yoshisato Esaka, vice president of Iguaçu.
Marubeni also introduced Iguaçu to the “5S Workplace Disciplines”: Seiri (sort), Seiton (set in order), Seiso (shine), Seiketsu (standardize), Shitsuke (sustain). Seen in its offices, manufacturing plants and throughout the company, these values help shape employee decorum. “5S is incorporated into everything we do…” adds Esaka. “This positive cycle motivates every one of us to do everything conscientiously.”
The coffee industry has experienced some difficult times in the past because of the price volatility in the coffee market. Having learned a lesson, Iguaçu basically—keeps their factory running 24 hours a day, 365 days a year—to maximize productivity and mitigate difficulties.
“You need to grow. There is no other choice,” says Iguaçu president Edivaldo Barrancos. He shares that Iguaçu is currently re-engineering its entire operation to define the future of the company.
“We always have opportunities to do some kaizen [the Japanese word for “improvement”],” he adds. “The key differentiator of Iguaçu is our people and the way they perform. In everything we do, we think about how to do it better.”
For now, Iguaçu beats out the competition with their ability to create custom blends. By using various raw ingredients, along with their state-of-the-art industrial processing capabilities, the company is able to churn out tailor-made creations for clients.
Creating that perfect, custom flavor starts with the Research and Development (R&D) Team, which runs extensive tests on reference samples sent by clients.
“We analyze it in all aspects: the sensorial, physical, moisture, and chemical,” says R&D coordinator Karina Kaminari Konno. The next step involves trying out recipes, which are done in what Konno describes as their “innovation laboratory.” This space enables them to carry out fast, full-scale product development without interrupting the plant’s manufacturing line. The experience of creating a unique blend, says Konno, made her “fall in love with coffee.”
It’s a similar story for many at Iguaçu; they have fallen in love not just with coffee, but also with the company. Barrancos himself is marking his 35th year in Iguaçu, and shares that many other employees decide to stay for a number of years, passing the coffee-making tradition to the next generation.
Esaka believes that the company’s strength comes from its employees, whom he sees as family. “Our philosophy is to provide the Brazilian coffee experience to people around the world by making affordable, yet high-quality products,” Esaka says. “We work together as a family toward our common goals, transforming Iguaçu into an even stronger company for the next 50 years.”
All information contained in this article is based on interviews conducted in December 2017.