Decaffeinated coffee: without caffeine, with taste

Decaffeinated: market trends in Italy, Europe and worldwide

TheItaly is the leading European producer of roasted coffee, with around 1,000 active companies, over 7,000 employees and a turnover of 5.7 billion euros in 2024 (Beverfood, 2025). The spread of decaffeinated coffee in daily habits appears increasingly relevant. A SWOA (Social Web Opinion Analysis) survey conducted in Italy in 2026 on 1,200 users between 20 and 50 years old highlights that 82% of consumers regularly alternate decaffeinated coffee with classic espresso, a sign of more flexible consumption linked to both taste and reduction of caffeine intake (ANSA, 2026).

The  European market leads the demand for decaffeinated coffee and holds 41% of the global value. Globally, the market was estimated at 3.18 billion USD in 2025 and is expected to reach 5.22 billion USD by 2033, with a compound annual growth rate (CAGR) of 6.7% between 2026 and 2033 (Grand View Research, 2026). Growth is driven by demand for low-caffeine beverages, an aging population, and broader availability of premium, organic, and specialty decaffeinated variants.

Technical evolution: the stages of industrial decaffeination

The birth of  decaffeinated coffee is linked to a story as curious as it is controversial. In  1906 Ludwig Roselius, a German entrepreneur and chemist, patented the first industrial decaffeination process, founding the company Kaffee in Bremen HAG (Handels-Aktien-Gesellschaft).

The original method used steam to open the pores of the green beans, followed by treatment with an extracting solvent. First benzene, then dichloromethane (methylene chloride), more selective and with a better toxicological profile.

In  1967 the Swiss company Coffex developed the  Swiss Water Process, free of chemical solvents, which became the reference for the organic and specialty segments. The 1980s saw the establishment of extraction with  Supercritical CO₂, capable of combining extraction efficiency and aromatic preservation.

Regulatory framework: EU rules and Italian limits on caffeine

Directive 1999/4/EC concerning coffee extracts and chicory extracts provides for the possibility to indicate the wording «decaffeinated» – on the label of «coffee extract», «soluble coffee extract», «soluble coffee» or «instant coffee» – when ‘The  caffeine content anhydrous is not higher, by weight, than the 0,3% of the dry substance obtained from coffee. This wording must appear in the same field of vision as the sales denomination’ (article 2.1.b).

In Italy – in the absence of harmonized European rules – the Ministry of Health has already established by decree on May 20, 1976 (modified by DM January 23, 1991, no. 87) the maximum levels of caffeine and moisture in decaffeinated coffee both raw and roasted:

• ‘raw coffee: must not contain more than 0,1% of anhydrous caffeine referred to 100 parts of dry substance; (…) moisture must not exceed the value of 11 percent of the product (this value is to be understood as weight loss recorded at 100 °C after six hours);

• roasted coffee: must not contain more than 0.1% of anhydrous caffeine referred to 100 parts of dry substance; moisture must not exceed 5 percent of the product weight’.

Directive 2009/32/EC on extraction solvents used in the preparation of foods in turn defines their conditions of use and the maximum amounts of respective residues. Regarding the decaffeination or removal of irritating and bitter substances from coffee and tea, the directive refers to:

• methyl acetate, maximum residue 20 mg/kg in tea and coffee;

• dichloromethane, 2 mg/kg in roasted coffee and 5 mg/kg in tea.

Extraction technologies: comparison of 4 industrial methods

The  decaffeination always takes place on green beans before roasting. The technical challenge is to selectively extract caffeine while minimizing the loss of  aromatic precursors - sugars, chlorogenic acids, trigonelline, and lipids - that develop the aroma during roasting.

Organic solvents (ethyl acetate or dichloromethane)

The beans are hydrated with steam, then exposed to an organic solvent: ethyl acetate (AcOEt) or dichloromethane (DCM). The solvent selectively bonds to caffeine; the complex is then removed by evaporation and the beans treated with pressurized steam to eliminate residues.

Theethyl acetate can derive from chemical synthesis or from natural fermentation of sugarcane or fruit. In the case of using AcOEt from natural fermentation, the decaffeination process can be defined as a ‘natural method’, in line with the ISO/TS 19657 technical specification (Dongo, 2019).

Swiss Water Process

Developed in Switzerland in the Sixties and applied at industrial level since the late Eighties, the  Swiss Water Process is free of chemical solvents. The beans are immersed in hot water (Green Coffee Extract, GCE) to extract all soluble substances. The solution then passes through  activated carbons which, by molecular affinity, selectively retain caffeine (but not also minor aromatic compounds). The process is allowed in production organic.

Supercritical CO₂

Carbon dioxide in the supercritical state — reached at pressures above 73.8 bar and temperatures over 31.1°C — behaves like a  highly selective solvent for caffeine, leaving most aromatic compounds and lipids intact. It does not produce residues in the final product and the CO₂ is recycled in the process. It is the method that best preserves the  organoleptic profile coffee, prevalent in the premium and specialty segment.

Mountain Water Process

The  Mountain Water Process, sviluppato in Messico con acqua glaciale del vulcano Pico de Orizaba, è una variante del Swiss Water Process a sua volta certificabile come organic. It is mainly used for coffee of Latin American origin intended for the specialty market. Some versions combine purified water and natural ethyl acetate as a secondary extraction step.

Bioactive compounds: what remains in coffee after extraction?

A cup of  decaffeinated espresso (about 30 ml) retains a significant share of the bioactive components of conventional coffee, despite the drastic reduction of caffeine alone. In particular:

• chlorogenic acids: 30–90% compared to untreated coffee; better preserved with supercritical CO₂ (Ludwig et al., 2014);

• trigonelline: precursor of niacin (vitamin B3), partially degraded by roasting; contributes to bitter notes;

• diterpenes (cafestol and kahweol): documented immunomodulatory properties; more abundant in unfiltered coffees (e.g. moka);

• calories: 1–5 kcal per cup (without added sugar).

The decaffeination method significantly influences the retention of chlorogenic acids: the supercritical CO₂ process preserves a larger share compared to aqueous treatment, which tends to remove part of them along with caffeine (Ludwig et al., 2014).

Decaffeinated coffee and health: scientific evidence

The umbrella review by Poole et al. (2017), published in the British Medical Journal – based on 201 meta-analyses, including 67 exposures and 45 outcomes – documents an association between coffee consumption, including decaffeinated coffee, and:

• reduced risk of  type 2 diabetes (association also documented for decaffeinated coffee alone);

• lower incidence of  liver diseases, including cirrhosis and hepatocellular carcinoma;

• inverse association with some cancers (endometrium, oral cavity, pharynx);

• reduced risk of  Parkinson's disease and cognitive decline (with still limited evidence on the specific contribution of decaffeinated coffee).

The subsequent review by Machado et al. (2024) integrates the evidence associating the bioactive compounds of coffee the various actions:

• neuroprotective (caffeine, chlorogenic acids, and melanoidins);

• anti-inflammatory (caffeine, chlorogenic acids, melanoidins, diterpenes);

• modulating the microbiota (polysaccharides, melanoidins, chlorogenic acids);

• immunostimulant (polysaccharides);

• antidiabetic (trigonelline, chlorogenic acids);

• anti-hypertensive (chlorogenic acids);

• cholesterol-lowering (polysaccharides, chlorogenic acids, lipids).

Specific research on decaffeinated coffee indicate some possible health benefits associated with its consumption, including:

• the reduction of type 2 diabetes risk, attributed to non-caffeine phenolic compounds, particularly chlorogenic acids (Bhupathiraju et al., 2014);

• the reduction of all-cause mortality, including cardiovascular mortality (Ding et al., 2014);

• protective effects against various chronic and degenerative diseases, linked to the presence of bioactive compounds (Ludwig et al., 2014).

Epidemiological results also describe statistical associations, not direct causality. Questions remain about confounding factors, individual variability, and data quality regarding decaffeinated consumption as a specific category.

Circular economy: reuse of caffeine in pharmaceuticals and cosmetics

Decaffeination is not only a subtraction process but a virtuous example of enhancement of by-products. The caffeine extracted from green beans is recovered and purified to be reintroduced into the production cycle of other sectors:

• beverage industry: is the main buyer of natural caffeine (often preferred over synthetic) for the formulation of energy drinks and cola-based beverages;

• pharmaceutical sector: caffeine is a key active ingredient in many analgesic drugs (enhancing their effect), anti-inflammatory drugs, and central nervous system stimulants;

• cosmetics: thanks to its lipolytic and draining properties, caffeine is used in anti-cellulite formulations, eye contour creams, and scalp care products.

This model of biorefinery allows companies to offset the high energy costs of decaffeination processes (especially supercritical CO₂), transforming an extraction residue into a high value-added secondary raw material.

Conclusions

The excellence of Italian roasting finds in decaffeinated coffee one of its highest expressions of innovation. The ability to manage complex extraction processes and enhance every component of the raw material places this product within modern circular economy protocols. For international markets, Italian 'deca' confirms itself as a high-quality option that meets a global demand increasingly oriented towards well-being and sustainability of production processes.

Dario Dongo

Bibliography

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• Beverfood (2025, September 23). Coffee Yearbook in Italy: Coffitalia 2025. https://www.beverfood.com/coffitalia-2025-annuario-caffe-bevande-calde

• Bhupathiraju, S. N., Pan, A., Malik, V. S., Manson, J. E., Willett, W. C., van Dam, R. M., & Hu, F. B. (2013). Caffeinated and caffeine-free beverages and risk of type 2 diabetes.  The American journal of clinical nutrition, 97(1), 155–166. https://doi.org/10.3945/ajcn.112.048603

• Ding, M., Bhupathiraju, S. N., Chen, M., van Dam, R. M., & Hu, F. B. (2014). Caffeinated and decaffeinated coffee consumption and risk of all-cause and cause-specific mortality.  Circulation, 129(6), 643–659. https://doi.org/10.1161/CIRCULATIONAHA.113.005925

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• Directive 2009/32/EC of the European Parliament and of the Council of 23 April 2009 on the approximation of the laws of the Member States on extraction solvents used in the production of foodstuffs and food ingredients (Recast). Consolidated text: 16/02/2023 http://data.europa.eu/eli/dir/2009/32/2023-02-16

• Dongo, D. (2019, January 1). Natural ingredients, the ISO-compliant ABC. FT (Food Times). https://www.foodtimes.eu/it/consumatori-e-salute/ingredienti-naturali-labc-a-norma-iso/

• Grand View Research. (2026). Decaffeinated Coffee Market Size, Share & Trends Analysis Report (2026–2033). https://www.grandviewresearch.com/industry-analysis/decaf-coffee-market

• Ludwig, I. A., Clifford, M. N., Lean, M. E., Ashihara, H., & Crozier, A. (2014). Coffee: biochemistry and potential impact on health.  Food & function, 5(8), 1695–1717. https://doi.org/10.1039/c4fo00042k

• Machado, F., Coimbra, M. A., Castillo, M. D. D., & Coreta-Gomes, F. (2024). Mechanisms of action of coffee bioactive compounds – a key to unveil the coffee paradox.  Critical reviews in food science and nutrition, 64(28), 10164–10186. https://doi.org/10.1080/10408398.2023.2221734

• Ministry of Health. Decree 23 January 1991, No. 87. Regulation containing amendments to the ministerial decree of 20 May 1976, concerning the regulation of the production and trade of decaffeinated coffee. Normattiva. https://www.normattiva.it/esporta/attoCompleto?atto.dataPubblicazioneGazzetta=1991-03-19&atto.codiceRedazionale=091G0122

• Poole, R., Kennedy, O. J., Roderick, P., Fallowfield, J. A., Hayes, P. C., & Parkes, J. (2017). Coffee consumption and health: Umbrella review of meta-analyses of multiple health outcomes.  BMJ, 359, j5024. https://doi.org/10.1136/bmj.j5024