Processing Beans
Didn't see the Discovery Channel show....but I can offer this much info.....
Large coffee operations pulp & wash the beans quickly. They then dry the beans in BIG round open machines, with a rotating "mixer" arm continually stirring the beans, fire below. Drying time is approximately 12-24 hours, depending on how hot the fire is! DEFINITELY, this does not turn out the same product as hand-washed, sun-dried beans!
By comparison, (very small operation!), we pulp the beans & then allow them to ferment for a day or two in water before washing them. Makes for cleaner coffee and the cleaner the coffee comes out at this point, the better! Sun-drying then takes days - sometimes days & days & days - depending on the weather, the humidity, etc. True test when the beans are properly dry....bite a bean. If you can't bite into it, it's done.
We store the beans at that point with the parchment shell still in tact. Keeps the coffee fresh almost forever; no bug problems; the bean is still a viable seed in fact.
We only remove the parchment shell and roast when someone orders coffee from us.