•Puffing is a novel alternative of roasting in coffee processing.•Puffing increased extraction yield and antioxidant capacity compared to roasting.•Puffing did not increase specific volume but increased extraction yield.•Chlorogenic acid and trigonelline contents significantly reduced with roasting. Puffing of coffee beans, which induces heat- and pressure-derived physicochemical changes, was applied as an alternative to roasting. Roasted or puffed coffee beans with equivalent lightness values were compared. The moisture content was higher while the crude fat and protein compositions were lower in puffed beans than in roasted beans. The pH was lower and the acid content was higher in puffed beans than in roasted beans. The roasted beans exhibited greater specific volumes, while the puffed beans displayed greater extraction yields. The trigonelline and total phenolic contents were greater in puffed beans than in roasted beans resulting in an enhanced antioxidant capacity. Sensory evaluation of roasted and puffed coffee bean brews revealed that puffing did not affect the flavor or overall acceptance. The current study provides evidence that puffing is an alternative to roasting coffee beans with various benefits.