How do I know if my roaster is at capacity?

Compare the green kilos you need each week with what the roaster produces at a comfortable charge, at three to four batches an hour, in the hours you are willing to roast.

Should my second roaster be the same make?

Not necessarily. Same make simplifies training and parts; a different size or design may suit the job better.

When to buy a second roaster (and which size)

A second roaster can mean more capacity, a backup for breakdowns, or a small machine for single origins and samples. The signs it is time, and how to choose between a bigger machine and a second one.

6 min read Updated 9 October 2026

Roasters usually feel the need for more capacity before the numbers show it, because roasting days get long and stressful. Before buying, check whether the problem is capacity, or scheduling, packing or a slow roaster that needs maintenance.

Signs it is time

Check these first

The roaster runs at near full charge for more hours than you want to roast, most weeks
Orders are turned away or delayed because of roasting time, not packing
One breakdown would stop all supply to wholesale accounts
Small single-origin and sample batches clog production days
Forecast volume for the next 12 to 24 months exceeds comfortable capacity

Bigger machine or a second machine?

	Replace with a bigger roaster	Add a second roaster
Capacity	Large step up	Adds capacity in a smaller step
Redundancy	None; one machine still stops everything	Either machine can keep key accounts supplied
Small batches	Harder; a big drum handles small charges poorly	A small second machine suits single origins and development
Space and services	Often a bigger flue, afterburner and gas supply	Two flues or a shared system; more floor space
Profiles	Every recipe redeveloped for the new machine	Existing recipes stay on the old machine

The numbers

Work out the extra gross margin the new capacity will earn (extra kilos multiplied by margin per kilo), and compare it with the full installed cost and running cost. If the extra volume is not yet sold, test with contract roasting or longer roasting days first. See gross margin per kg.

Where Roastnet helps

Questions roasters ask

How do I know if my roaster is at capacity?: Compare the green kilos you need each week with what the roaster produces at a comfortable charge, at three to four batches an hour, in the hours you are willing to roast.
Should my second roaster be the same make?: Not necessarily. Same make simplifies training and parts; a different size or design may suit the job better.