Evaluation of energy transition pathways for the instant coffee industry

Instant coffee (IC) manufacturing is among the most energy-intensive processes in the food and beverage industry, requiring substantial amounts of heat and electricity, and generating significant CO₂ emissions. This study evaluates multiple decarbonization pathways—including fuel switching, process electrification, CO₂ capture and storage (CCS), and energy efficiency—through a systematic techno-economic assessment. Results show that conventional natural gas-based (NG) production emits above 2.5 tCO₂/t_IC. Fuel switching towards biomethane and biomass results in CO₂ emission reductions up to 86% while remaining economically competitive. Electrification reduces energy demand by 6% and can lower emissions by up to 72% with a decarbonized electricity grid. Similarly, the carbon footprint of hydrogen-based systems strongly depends on hydrogen origin: grey hydrogen emits about 3.5 tCO₂/t_IC, whereas green hydrogen can achieve reductions of 68–75% compared to ‘NG’. However, hydrogen remains prohibitively expensive under current market conditions. CC enables further reductions and even net-negative emissions (–0.2 to –2.88 tCO₂/t_IC) when combined with bioenergy, albeit with additional energy demand (+15–26% compared to NG) and higher costs. Regional analysis highlights stronger prospects for biomethane and electrification in Nordic countries, while NG-based systems remain economically favored in Southern Europe. The study emphasizes the importance of favorable energy prices, higher carbon pricing, sustainable biomass availability, electricity grid reinforcement, and waste heat recovery integration for the long-term decarbonization of the IC industry.