U.S. patent application number 14/412034 was filed with the patent office on 2015-06-11 for method for packaging a beverage powder in a beverage capsule.
The applicant listed for this patent is Nestle S.A.. Invention is credited to Christian Guenat, Carlo Magri, Patricia Ann Mathias, Peter Merckaert, Olivier Villain.
Application Number | 20150158609 14/412034 |
Document ID | / |
Family ID | 48672639 |
Filed Date | 2015-06-11 |
United States Patent
Application |
20150158609 |
Kind Code |
A1 |
Villain; Olivier ; et
al. |
June 11, 2015 |
Method for Packaging a Beverage Powder in a Beverage Capsule
Abstract
A method for packaging in a capsule a beverage powder tending to
evolve a gas, said capsule comprising a capsule body (103) defining
a cavity (106) containing a quantity of beverage powder, said
cavity being hermetically sealed up comprises the following steps:
providing a quantity of said beverage powder evolving a gas within
said cavity (106) of said capsule body (103); applying a vacuum
into said cavity (106) of the capsule body (103), so that the
internal pressure in the cavity (106) is below atmospheric
pressure; sealing the capsule to hermetically close said cavity
(106), while maintaining the internal pressure in the cavity (106),
below atmospheric pressure; and keeping said gas emanating into the
cavity (106) of the capsule so that the internal pressure in the
sealed-up capsule is above atmospheric pressure. Use for packaging
in a capsule a ground coffee.
Inventors: |
Villain; Olivier; (Vevey,
CH) ; Mathias; Patricia Ann; (Blonay, CH) ;
Magri; Carlo; (Collombey, CH) ; Merckaert; Peter;
(Lausanne, CH) ; Guenat; Christian; (L'Auberson,
CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nestle S.A. |
Vevey |
|
CH |
|
|
Family ID: |
48672639 |
Appl. No.: |
14/412034 |
Filed: |
June 25, 2013 |
PCT Filed: |
June 25, 2013 |
PCT NO: |
PCT/EP2013/063175 |
371 Date: |
December 30, 2014 |
Current U.S.
Class: |
426/112 ;
53/432 |
Current CPC
Class: |
B65B 29/022 20170801;
B65B 31/042 20130101; B65B 7/164 20130101; B65D 85/8043 20130101;
B65B 31/028 20130101; B65D 77/003 20130101 |
International
Class: |
B65B 31/04 20060101
B65B031/04; B65B 7/28 20060101 B65B007/28; B65D 85/804 20060101
B65D085/804 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 4, 2012 |
EP |
12174911.3 |
Claims
1. A method for packaging in a capsule a beverage powder tending to
evolve a gas, said capsule comprising a capsule body defining a
cavity containing a quantity of beverage powder, said cavity being
hermetically sealed up or respectively, the capsule being
hermetically sealed up by an over-packaging, the method comprising
the steps of: providing a quantity of said beverage powder evolving
a gas within said cavity of said capsule body; applying a vacuum
into said cavity of the capsule body, or respectively, into said
over-packaging containing the capsule, so that the internal
pressure in the cavity, or respectively, in said over-packaging is
below atmospheric pressure; sealing the capsule to hermetically
close said cavity, or respectively, sealing the over-packaging to
hermetically close the over-packaging surrounding the capsule while
maintaining the internal pressure in the cavity, or respectively,
in said over-packaging below atmospheric pressure; and keeping said
gas emanating into the hermetically closed cavity of the capsule so
that the internal pressure in the sealed-up capsule, or
respectively, in said over-packaging, is above atmospheric
pressure.
2. A method according to claim 1, wherein said beverage powder is a
ground coffee, and wherein the method further comprises a step of
grinding coffee beans before said step of sealing, and wherein the
duration of a degassing step between grinding the coffee beans and
sealing the cavity, or respectively, sealing the over-packaging is
less than 25 minutes.
3. A method according to claim 1, wherein the pressure reduction
below atmospheric pressure applied into the cavity, or
respectively, into the over-packaging, in the step of applying a
vacuum, is comprised between 100 and 800 mbar.
4. A method according to claim 1, wherein after said keeping step,
the internal pressure is comprised between 1050 mbar and 1800
mbar.
5. A method according to claim 4, wherein said internal pressure is
stabilized to a value comprised between 1050 mbar and 1800 mbar
about 72 hours after said sealing step.
6. A method according to claim 1, wherein the capsule is sealed
hermetically by sealing a membrane onto the capsule body.
7. A method according to claim 6, wherein the membrane is sealed
onto a flange of the capsule body by heat welding or ultrasonic
sealing.
8. A method according to claim 1, wherein the capsule is gas
permeable and is contained within said hermetically sealed
over-packaging.
9. A beverage capsule comprising a capsule body defining a cavity
and being adapted to be hermetically sealed up with a quantity of
beverage powder provided within said cavity, wherein the beverage
capsule is fabricated by the method of packaging according to claim
1.
10. A beverage capsule according to claim 9, wherein said cavity is
provided with a predetermined quantity of roast and ground
coffee.
11. A beverage capsule according to claim 10, wherein said cavity
is provided with a quantity of roast and ground coffee comprised
between 4 and 16 grams.
12. A beverage capsule according to claim 10, wherein at the
equilibrium (after full degassing), said cavity has a volume
between 8 to 30 ml.
Description
CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE
STATEMENT
[0001] This application is a US national stage application filed
under 35 USC .sctn.371 of International Application No.
PCT/EP2013/063175, filed Jun. 25, 2013; which claims benefit of EP
Application No. 12174911.3, filed Jul. 4, 2012. The entire contents
of the above-referenced applications are hereby expressly
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The presently disclosed and/or claimed inventive concept(s)
relates generally to a method for packaging a beverage powder
tending to evolve a gas in a beverage capsule. It also relates to a
beverage capsule so produced. In particular, the presently
disclosed and/or claimed inventive concept(s) relates to such
capsules as adapted for coffee beverages.
BACKGROUND
[0003] Coffee beans, before being used to prepare a coffee
beverage, must generally be roasted. This process induces numerous
chemical reactions and physical changes within the coffee beans,
which must be accounted for when packaging the roasted coffee.
[0004] The roasting process is what produces the characteristic
flavor of coffee by causing the green coffee beans to expand and to
change in color, aroma and density. The oils and aromatic volatiles
contained and/or developed during roasting confer the aroma and
flavor of the coffee beverage produced therefrom, but are also
prone to degradation when exposed to the oxygen in the surrounding
air. It is thus important to protect the roasted coffee from the
surrounding air, to maintain optimal freshness and shelf life. The
roasting process also causes the production of gases within the
coffee beans, primarily carbon dioxide and carbon monoxide. These
gases are slowly evolved by the coffee subsequent to roasting in a
process called "degassing." Grinding the roasted coffee beans will
accelerate this process.
[0005] Recently, it has been common to base beverage production
systems on the principle of portioned beverages; that is, providing
a pre-determined volume of a beverage upon demand. This has been
typically accomplished by providing a capsule, which contains a
pre-portioned amount of a beverage powder, most commonly ground
coffee. Hot water is then introduced into the capsule to prepare
the beverage, which is then dispensed into a container for
consumption. Before use, the capsule can be hermetically sealed
under vacuum or controlled atmosphere such as mentioned in
WO8602537 to reduce oxidation by the contact of coffee with air.
While this specification refers to a "capsule," it is understood
those other terms, such as "pod," "cartridge," or "packet" may be
employed instead.
[0006] Such capsules may be configured so as to be hermetically
sealed up until use. It is evident that by such hermetical sealing,
it is meant that a gas transfer is not made possible in any
direction between the inside of the capsule and the external
atmosphere at least for many months. This is desirable, as the
capsule will prevent the essential oils present in the coffee from
degradation caused by contact with oxygen in the air. This improves
the flavor and shelf life of the coffee within such a capsule. It
is also evident that due to its hermetical closure, the capsule is
configured for a single use.
[0007] However, as described above, coffee will evolve gas after
roasting. When the ground coffee is packaged in a sealed container,
the container will trap any gases evolved by the coffee contained
within, which in some cases may cause the container to rupture
under the pressure generated by the evolved gas. The container must
be constructed more robustly, requiring more materials for its
construction and increasing the cost of its fabrication.
[0008] To avoid this, the coffee is held aside for a period of
time, allowing substantially all of the gases to be released from
the coffee before it is packaged in containers. This process is
known in the art as "degassing." By degassing the coffee
beforehand, one may avoid the evolution of gas within the sealed
container and the accompanying accumulation of pressure.
[0009] However, the step of degassing beforehand coffee causes a
loss of aromatic compounds. This aroma loss reduces the aroma
intensity and modifies the aromatic profile of the final beverage
obtained from the extraction of the beverage capsule.
[0010] The degassing process is generally accomplished by the use
of degassing silos or buffers, within which the coffee is stored
while it degasses. The silos are generally provided with means for
removing the evolved gases, and may optionally be provided with
means for introducing an inert gas. This inert gas, generally
nitrogen, excludes oxygen from the silos and prevents degradation
of the coffee.
[0011] One must store the degassing coffee within these silos for
as long as is necessary to evacuate a sufficient amount of gas. For
ground coffee, the degassing time is usually between 30 and 60
minutes for a partial degassing to 24 hours or more for a full
degassing. However during degassing, a large part of volatiles
aromas of the coffee are lost, diminishing the flavor and the aroma
of the coffee beverage.
[0012] Of course, degassing of the coffee cannot be totally
eliminated between the grinding and the sealing of the capsule
since the coffee must be transported from the grinding area to the
filling and sealing areas. This "transport degassing" is dependent
on the production line capacity.
[0013] WO2008129350 refers to a machine for packaging capsules in a
vacuum and/or in a controlled atmosphere. After filling with
coffee, the capsules are partially closed by an hermetic film.
Then, a vacuum is formed inside the capsules and sealed by a
thermo-sealing vacuum device. Optionally, an inert gas can be
inserted in the capsule after drawing a vacuum to fill the
headspace of the capsule with a controlled atmosphere. This
invention does not deal with a better preservation of the aroma of
the packaged product. In particular, there is no indication that
the degassing of the product is minimized before the capsule is
hermetically sealed and gas is kept emanating into the cavity.
[0014] In U.S. Pat. No. 3,077,409, the invention seeks to eliminate
the holding (degassing) period for coffee before packing it. It so
relates to a coffee package with a self-venting reclosure can. The
coffee is immediately filled into the can, thus omitting the
conventional holding cycle. The filled can is then closed under
vacuum. The can comprises a valve means permitting a portion of the
gas within the container to pass. However, the problem of
preserving aroma is not tackled since the evolving gas is allowed
to escape out of the capsule.
[0015] U.S. Pat. No. 4,069,349 refers to a process for vacuum
packaging of roasted ground coffee in pouches. The pouches are
partially sealed, with a tortuous unsealed passage, and then stored
for a predetermined period of time to permit the gases to evolve
from the pouches and then sealing the pouches to prevent further
gaseous passage to and from the product. The degassing of the
product outside the pouch causes the loss of aromatic
compounds.
[0016] WO2011039711 relates to a method and machine for packing
infusion product into capsules; the machine comprising a series of
station for manipulating, filling, sealing and overwrapping the
capsules and all enclosed within a zone in controlled atmosphere
(using nitrogen, for example) so as to preserve the chemical and
physical qualities of the product, for example, aroma in the
coffee. However, there is no reduction of degassing of the product
before sealing and overwrapping the capsule; no vacuum is drawn in
the package before sealing and no degassing of the product is
contemplated in the package to an extent above the atmospheric
pressure. WO2010007633 refers to a machine for packaging products,
in particular capsules for machines for delivering infusion
beverages. A vacuum bell provides vacuum around each capsule to be
welded. At the same time, vacuum compensating means take care of
inserting gas, in particular nitrogen, inside each capsule in such
a way to compensate the presence of vacuum. Afterwards, the welding
means take care of welding the aluminium sheet onto the edge of the
respective capsule. Typically, the product must be degassed before
closure of the capsule to prevent over-pressure due to the presence
of the compensating gas. Such degassing causes the loss of volatile
aromatic compounds.
[0017] Therefore, the presently disclosed and/or claimed inventive
concept(s) includes a method for the packaging of a beverage powder
tending to evolve a gas in a capsule, in which the flavor and aroma
of the beverage powder are better preserved, that overcome the
defects and disadvantages of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Other particularities and advantages of the presently
disclosed and/or claimed inventive concept(s) will also emerge from
the following description.
[0019] In the accompanying drawings, given by way of non-limiting
examples:
[0020] FIG. 1 is a series of orthogonal section views depicting an
attachment means, a cutting means, a vacuum-application means, and
a sealing means adapted to perform a method of packaging according
to an embodiment of the presently disclosed and/or claimed
inventive concept(s);
[0021] FIG. 2 is a series of orthogonal views of attachment
apparatuses in four different configurations;
[0022] FIG. 3 is a flowchart depicting an embodiment of the method
of packaging as integrated into a process for the fabrication of
beverage capsules; and
[0023] FIG. 4 is a schematic view of a method for packaging a
capsule in a sealing over-packaging according to an alternative
embodiment of the presently disclosed and/or claimed inventive
concept(s).
DETAILED DESCRIPTION
[0024] The presently disclosed and/or claimed inventive concept(s)
relates generally to a method for packaging a beverage powder
tending to evolve a gas in a beverage capsule. It also relates to a
beverage capsule so produced. In particular, the presently
disclosed and/or claimed inventive concept(s) relates to such
capsules as adapted for coffee beverages.
[0025] According to a first aspect, the presently disclosed and/or
claimed inventive concept(s) is directed to a method for packaging
in a capsule a beverage powder tending to evolve a gas, said
capsule comprising a capsule body defining a cavity containing a
quantity of beverage powder, said cavity being hermetically sealed
up or respectively, the capsule being hermetically sealed up by an
over-packaging.
[0026] The packaging method comprises the following steps: (i)
providing a quantity of said beverage powder evolving a gas within
said cavity of said capsule body; (ii) applying a vacuum into said
cavity of the capsule body or respectively, into said
over-packaging containing the capsule, so that the internal
pressure in the cavity, or respectively, in said over-packaging is
below atmospheric pressure; (iii) sealing the capsule to
hermetically close said cavity, or respectively, sealing the
over-packaging to hermetically close the over-packaging surrounding
the capsule while maintaining the internal pressure in the cavity,
or respectively, in said over-packaging below atmospheric pressure;
and (iv) keeping said gas emanating into the hermetically sealed
cavity of the capsule so that the internal pressure in the
sealed-up capsule, or respectively, in said over-packaging, is
above atmospheric pressure.
[0027] This is advantageous in that it permits the packaging of a
quantity of beverage powder in a capsule after a limited degassing,
a further degassing of the coffee instead occurring within the
sealed beverage capsule itself or respectively within the
over-packaging sealing-up the capsule.
[0028] According to a principle of the presently disclosed and/or
claimed inventive concept(s), the vacuum created within the
beverage capsule, or respectively within the over-packaging, before
the capsule or respectively the over-packaging is sealed,
compensates for the pressure generated by the gases evolved from
the coffee. The accumulation of evolved gas is thus prevented from
building to a pressure that might compromise the integrity of the
capsule or respectively of the over-packaging.
[0029] Since the coffee is not significantly degassed before sealed
into the beverage capsule, the volatile aroma and flavor compounds
of the beverage produced therefrom are preserved and maintained in
the capsule or respectively, in the over-packaging.
[0030] In a practical way, when the beverage powder is a ground
coffee, the method comprises a step of grinding coffee beans before
the step of sealing, the duration of a degassing step between
grinding the coffee beans and sealing the cavity, or respectively,
sealing the over-packaging is less than 25 minutes, such as but not
limited to, less than 20 minutes, or comprised between 5 and 15
minutes.
[0031] Thus the degassing time is reduced, and in any event, is
shorter than the duration requested in prior packaging method used
to encapsulate ground coffee in a hermetically close capsule.
[0032] According to a feature, the pressure reduction below
atmospheric pressure applied into the cavity, or respectively, into
the over-packaging, in the step of applying a vacuum, is comprised
between 100 and 800 mbar, such as but not limited to, between 250
and 700 mbar, or between 300 and 600 mbar.
[0033] These values are well adapted to compensate the increase of
pressure in the capsule body due to the gas evolved by the beverage
powder after sealing of the capsule body.
[0034] The atmospheric pressure is the value of the pressure at the
location where the step of applying a vacuum occurs.
[0035] After the keeping step, the internal pressure is comprised
between 1050 mbar and 1800 mbar, such as but not limited to,
between 1050 and 1600 mbar, or between 1050 and 1350 mbar.
[0036] The internal pressure is stabilized to a value comprised
between 1050 mbar and 1800 mbar, such as but not limited to,
between 1050 and 1600 mbar, or between 1050 and 1350 mbar, about 72
hours after said sealing step.
[0037] This internal pressure is acceptable in term of
manufacturing a sealed-up capsule and is compatible with a 12 month
shelf-life for the beverage capsules.
[0038] According to a second aspect, the presently disclosed and/or
claimed inventive concept(s) concerns a beverage capsule comprising
a capsule body defining a cavity and being adapted to be
hermetically sealed up with a quantity of beverage powder provided
within said cavity, fabricated by the method of packaging as
described above.
[0039] The beverage capsule so fabricated will embody the
advantages of the method as detailed above.
[0040] According to an advantageous embodiment of the presently
disclosed and/or claimed inventive concept(s), the cavity is
provided with a predetermined quantity of roast and ground
coffee.
[0041] In certain particular, non-limiting embodiments, the cavity
is provided with a quantity of roast and ground coffee comprised
between 4 and 16 grams, such as but not limited to, between 5 and
13 grams. At the equilibrium (after full degassing), the cavity of
the capsule has also a volume such as but not limited to, between 8
to 30 ml, or between 10 to 20 ml, or between 12 to 16 ml.
[0042] The following description will be given with reference to
the above-mentioned figures.
[0043] FIG. 1 is a sequence of section views depicting the sealing
of a beverage capsule according to the presently disclosed and/or
claimed inventive concept(s). FIG. 1 depicts the attachment and
cutting steps in views A through D, and the vacuum application and
sealing steps in views E through H. Portions of the apparatus are
omitted from each of these views for purposes of clarity.
[0044] View A depicts an attachment means 100 and a cutting means
101 disposed in a first position, prior to the start of an
attachment step. The attachment means 100 and the cutting means 101
are generally tubular and coaxial about the first longitudinal axis
102.
[0045] A capsule body 103 is positioned within the base plate 104,
which is provided with a capsule seat 105 in which the capsule body
103 is positioned. In certain particular, non-limiting embodiments,
the base plate 104 is configured to be mobile, facilitating a high
rate of production of beverage capsules. This mobile configuration
may comprise such means as a conveyor belt system or rotating
turret, for example. In the particular, non-limiting embodiment,
the capsule body 103 is positioned beneath the attachment means 100
and cutting means 101 so as to be coaxial with them about the first
longitudinal axis 102.
[0046] The capsule body 103 defines a cavity 106, in which a
predetermined quantity of roast and ground coffee powder 107 is
provided. The capsule body 103 is substantially cup-shaped, and is
provided with an open end 108 communicating with said cavity 106.
The capsule body 103 is further provided with a flange 109,
disposed about the circumference of the capsule body 103 at the
open end 108.
[0047] In certain particular, non-limiting embodiments, the capsule
body 103 is fabricated from a formable material such as aluminum,
plastic, starch, cardboard, or combination thereof. Where the
capsule body itself is not gas-impermeable, a gas barrier layer may
be incorporated therein to prevent the entry of oxygen. The gas
barrier may comprise a coating, film, or layer of a gas-impermeable
material such as aluminum, ethylene vinyl alcohol, polyamide,
oxides of aluminum or silicon, or combinations thereof.
[0048] For example, in one embodiment, the capsule body 103 is
formed of deep-drawn aluminum. In another embodiment, the capsule
body 103 is formed of deep-drawn polypropylene and aluminum. In a
third embodiment, the capsule body 103 is thermoformed from a
combination of polypropylene, ethylene vinyl alcohol, and
polyethylene terephthalate.
[0049] In a particular, non-limiting embodiment, the flange 109 and
the capsule seat 105 are configured so that the capsule body 103
protrudes through the base plate 104, with the flange 109 resting
directly on the base plate 104 and substantially the entire
beverage capsule 103 being disposed beneath the base plate 104. In
one alternate configuration, the capsule seat may be configured as
a cup, in which the capsule body is seated.
[0050] A portion of membrane material 110 is disposed between the
cutting means 101 and the base plate 104. In certain particular,
non-limiting embodiments, said membrane material 110 is provided in
the form of a continuous sheet or web, which may be fed into the
apparatus by techniques adapted from those known in the art of
materials handling. In certain particular, non-limiting
embodiments, the membrane material 110 is flexible, permitting
moderate elastic deformation. The membrane material 110 may have a
thickness between 10 and 250 microns, such as but not limited to,
between 30 and 100 microns.
[0051] In a particular, non-limiting embodiment, the membrane
material 110 comprises at least a base layer fabricated of
aluminum, polyester (e.g. PET or PLA), polyolefin(s), polyamide,
starch, paper, or any combination thereof. In certain particular,
non-limiting embodiments, the base layer is formed of a laminate
comprising two or more sub-layers of these materials. The base
layer may comprise a sub-layer which acts as a gas barrier, if none
of the other sub-layers are of a material which is impermeable to
gas. The gas barrier sub-layer is fabricated from aluminum,
ethylene vinyl alcohol, polyamide, oxides of aluminum or silicon,
or combinations thereof. In certain particular, non-limiting
embodiments, the membrane material 110 also comprises a sealant
layer, e.g. polypropylene, disposed to create a seal with the
capsule body 103.
[0052] For example, in one embodiment the membrane material 110 is
an aluminum layer between 25 and 40 microns. In another embodiment,
the membrane material 110 comprises a base layer with two
sub-layers: an external sub-layer made of PET and an internal
sub-layer made of aluminum. The aluminum sub-layer serves the
function of preventing undesirable transmission of light, moisture,
and oxygen. In another embodiment, the membrane material 110
comprises three sub-layers: an external sub-layer of PET 5 to 50
microns thick, a middle sub-layer of aluminum 5 to 20 microns
thick, and an internal sub-layer of cast polypropylene 5 to 50
microns thick.
[0053] View B depicts the apparatus in a second position, during a
cutting step. The cutting means 101 is advanced downward along the
first longitudinal axis 102 into the membrane material 110. In a
particular, non-limiting embodiment, the cutting means 101 is
sharpened along its peripheral edge 111 so as to cut the membrane
material 110 when pressed into it. However, alternate
configurations, such as a hot-knife apparatus, may be preferable
for certain compositions of heat-sensitive membrane material. The
cutting means 101 is advanced through the membrane material 110,
cutting a membrane 112 of the desired size and shape from the
membrane material 110.
[0054] View C depicts the apparatus in a third position, during an
attachment step. At the lower end 113 of the attachment means 100
are disposed a plurality of faces disposed substantially
perpendicular to the longitudinal axis 102, which are pressed into
the membrane 112. The attachment means 100 is advanced so that the
lower end 113 presses the membrane 112 into the flange 109 over a
plurality of regions corresponding to the aforementioned faces.
[0055] The attachment means 100 is configured to attach the
membrane 112 to the flange 109 over the regions where the faces of
the lower end 113 press said membrane 112 into the flange 109 of
the capsule body 103. In the present embodiment, the attachment of
the membrane 112 to the flange 109 of the capsule body 103 is
achieved by heat-sealing; though in other non-limiting embodiments,
alternate techniques such as ultrasonic welding may be
preferred.
[0056] In certain particular, non-limiting embodiments, the
attachment means 100 is furnished with appropriate means for
attaching the membrane 112 to the flange 109 during the attachment
step. For example, such means may comprise an electrical resistance
heater, hot air jet, or ultrasonic welding horn. This will make the
apparatus more compact and space-efficient.
[0057] Said regions of the flange 109 corresponding to the faces of
the lower end 113 of the attachment means 100 will comprise a
portion of the total surface of the flange 109. The cavity 106 of
the capsule body 103 thereby remains in communication with the
surrounding atmosphere, via the spaces between the flange 109 and
the membrane 112 where the membrane 112 remains unattached to the
flange 109.
[0058] View D depicts the apparatus in a fourth position, after the
completion of the attachment step. The attachment means 100 and
cutting means 101 are withdrawn from the capsule body 103 and
membrane 112. The scrap membrane material 110 may be removed, while
the base plate 104 is advanced in direction 114 to both place the
current beverage capsule in position for vacuum sealing and bring
the next beverage capsule into position for the attachment and
cutting steps.
[0059] In certain particular, non-limiting embodiments, the step
for cutting the membrane 112 as depicted in View B and the step for
attaching said membrane 112 to the flange 109 as depicted in View C
are performed sequentially but in a continuous movement of descent
of the cutting and attachment means 101, 100. A slight vacuum is
further applied through the attachment means to maintain the
membrane 112 in coaxial position in axis 102 during the cutting and
attachment steps. This is advantageous, in that it minimizes the
time to fabricate a capsule and thus increases the rate at which
capsules are produced.
[0060] View E depicts the apparatus in a fifth position, prior to
the start of a sealing step. In certain particular, non-limiting
embodiments, the vacuum-application means 115 and the sealing means
116 are tubular and disposed coaxially about the second
longitudinal axis 117. The cutting and attachment means depicted in
the previous steps are omitted here for clarity; however, the
cutting and attachment means are ideally disposed adjacent or in
close proximity to the vacuum-application means 115 and sealing
means 116, making the apparatus more compact and
space-efficient.
[0061] The base plate 104 is advanced in the direction 114 until
the capsule body 103 and membrane 112 are also coaxial with the
vacuum-application means 115 and the sealing means 116 about the
second longitudinal axis 117. The capsule body 103 and membrane 112
are thus positioned in a centered position directly below the
vacuum-application means 115 and sealing means 116.
[0062] View F depicts the apparatus in a sixth position, during a
vacuum-application step. The vacuum-application means 115 have been
advanced so as to create an airtight seal between the mouth 118 of
the vacuum-application means 115 and the flange 109 of the capsule
body 103. A vacuum 119 is applied to the capsule body 103 through
the vacuum-application means 115, reducing the pressure in the
cavity 106 of the capsule body 103 below atmospheric pressure. The
gas within the cavity 106 of the capsule body 103 is drawn out
through the plurality of spaces between the flange 109 and the
membrane 112, which are defined by the regions where said membrane
112 remains unattached to said flange 109. The gas can be air or
any inert gas such as nitrogen, CO.sub.2 or a combination thereof.
In this way, the cavity 106 of the capsule body 107 is voided of
gas without also sucking any of the coffee powder 107 from the
cavity 106. In this way, the aspiration of the coffee powder into
the apparatus or its entrainment between the flange 109 and
membrane 112 is avoided.
[0063] In certain particular, non-limiting embodiments, the
vacuum-application step is configured so that the vacuum may be
rapidly applied to the capsule body 103 while avoiding sucking the
coffee powder 107 from the cavity 106. It is known that the rapid
application of a vacuum to a beverage capsule may cause some of the
coffee powder within to be sucked out, which may result in damage
to the apparatus from aspirated coffee powder. The coffee powder
may also become entrained between the sealing surfaces of the
beverage capsule, weakening the seal and diminishing its aesthetic
properties. The application of vacuum may also cause the sealing
means to move, further compromising seal integrity.
[0064] Here, the attachment of the membrane 112 to the flange 109
of the capsule body 103 over a plurality of regions will prevents
the aspiration and entrainment of the coffee powder 107 between the
flange 109 and the membrane 112, as well as prevent the
displacement of the membrane relative to the capsule body during
the application of the vacuum 119. The integrity of the beverage
capsule seal and the reliability of the sealing apparatus are thus
preserved even when the vacuum is applied very rapidly, permitting
higher-quality beverage capsules to be produced at a faster
rate.
[0065] In certain particular, non-limiting embodiments, the
vacuum-application step is also configured to enable the conditions
within the capsule to be monitored as the vacuum 119 is applied.
Specifically, the vacuum-application means permits the rapid
application of the vacuum 119 to a single capsule body 103, rather
than the slower application of a vacuum to a group of capsule
bodies in a vacuum chamber. Thus, by use of data collection and/or
control-loop methods known in the art, one may continually adapt
the parameters of the vacuum-sealing process to optimize the
sealing of each capsule while still maintaining an overall high
rate of production.
[0066] View G depicts the apparatus in a seventh position, during a
sealing step. The mouth 118 of the vacuum-application means 115 is
kept in contact with the flange 109 of the capsule body 103, such
that the vacuum within the cavity 106 of the capsule body 103 is
maintained. The sealing means 116 is advanced into contact with the
membrane 112, pressing into it along the sealing edge 120 disposed
at an end of said sealing means 116. The membrane 112 is pressed
into the flange 109 by the sealing means 116, thereby bonding the
remaining unattached regions of the membrane 112 to the surface of
the flange 109 and hermetically sealing the membrane 112 to the
capsule body 103. While the remaining unattached regions of the
membrane are bonded, the bond of the attached regions created
during the attachment step may be renewed. The air-tight hermetic
seal created between the flange 109 and the membrane 112 will
thereby preserve the vacuum in the cavity 106 of the capsule body
103, protecting the coffee powder 107 from exposure to air and
subsequent loss of flavor and aroma.
[0067] View H depicts the sealed beverage capsule after the
completion of the sealing step. The sealing means 116 is withdrawn
to allow the bond to solidify. Then the vacuum is stopped in the
vacuum means exposing the capsule body 103 and membrane 112 to
atmospheric pressure and causing the membrane 112 to take a concave
form as depicted. Finally, the vacuum-application means 115 is
withdrawn. The vacuum which was applied to the capsule body 103 in
an earlier step is preserved therein by the seal between the flange
109 and the membrane 112. The base plate 104 is then moved off in
direction 114, removing the capsule to be packaged and distributed
and bringing the next capsule into position for vacuum sealing.
[0068] Immediately after the completion of the vacuum-sealing step,
the membrane 112 will be deflected inwardly into the capsule body
103, a result of the vacuum within the beverage capsule and
exposure to the atmospheric pressure.
[0069] As a result of chemical processes triggered by the roasting
process, the coffee powder 107 within the beverage capsule
degasses, the gases which are evolved are kept within the cavity
106 of the beverage capsule by the membrane 112, the capsule body
103, and the hermetic seal between the two. This accumulation of
evolved gases will cause the pressure within the beverage capsule
to increase until equilibrium pressure is reached. At equilibrium,
there will be a positive pressure within the beverage capsule, i.e.
a pressure above the atmospheric pressure, causing the membrane 112
to be deflected outwardly.
[0070] The vacuum which is sealed into the beverage capsule thus
partially offsets the pressure generated by the gases evolved from
the coffee powder 107. The degree to which the vacuum offsets the
evolved gases may vary from embodiment to embodiment, depending on
the volume of the beverage capsule, the mass of coffee provided
within, and the type and degree of roast of the coffee powder
itself. In any case, the vacuum within the beverage capsule
compensates for the degassing at least to the extent that the
evolved gas is prevented from compromising the structural integrity
of the beverage capsule and its hermetic properties.
[0071] In a particular, non-limiting embodiment, the pressure
reduction below atmospheric pressure is comprised between 100 and
800 mbar, such as but not limited to, between 250 to 700 mbar or
between 300 and 600 mbar. After the beverage capsule is sealed, the
gases evolved by the coffee powder during degassing will continue
to accumulate in the cavity 106 of the beverage capsule, causing
the internal pressure of the beverage capsule to rise above
atmospheric pressure in approximately 5 hours. In certain
particular, non-limiting embodiments, the internal pressure of the
beverage capsule will reach equilibrium between 1050 and 1800 mbar,
such as but not limited to, between 1050 and 1600 mbar, or between
1050 and 1350 mbar, in approximately 72 hours after the sealing of
the capsule.
[0072] Additionally, the method may be configured so that all, or
substantially all, of the degassing occurs within the beverage
capsule after it has been sealed. While the pressure within the
beverage capsule will be negative at time of sealing, the evolved
gases will rapidly increase the pressure within the capsules. In a
particular, non-limiting embodiment, the capsule will rise above
atmospheric pressure in less than 5 hours and stabilize in
approximately 72 hours.
[0073] FIG. 2 is a series of orthogonal views depicting a series of
configurations for the attachment means. As discussed above, the
attachment means comprises at its bottom end a plurality of faces,
which are pressed into the membrane to attach it to the flange of
the capsule body over a plurality of regions corresponding to said
faces.
[0074] FIG. 2A depicts an attachment means provided with two faces
200 of a first kind. The faces 200 of a first kind are separated by
two channels 201 of a first kind. When pressed into a membrane
during the attachment step as described above, the membrane will be
attached to a flange of a capsule body over the portion of the
surface of the flange corresponding to the faces 200 of a first
kind, while remaining unattached and permitting fluid communication
between the cavity of the capsule body and the surrounding
atmosphere. Upon the application of a vacuum, the air in the
capsule body will flow out through the unattached regions between
the membrane and flange defined by the channels 201 of a first
kind.
[0075] FIG. 2B depicts an attachment means provided with four faces
202 of a second kind, separated by four channels 203 of a second
kind. Such an attachment means will attach a membrane to a flange
of a capsule body over a plurality of regions corresponding to each
of the four faces 202 of a second kind, while leaving the regions
of the membrane corresponding to the four channels 203 of a second
kind unattached.
[0076] FIG. 2C depicts an attachment means provided with eight
faces 204 of a third kind, separated by eight channels 205 of a
third kind. As above, the faces 204 of a third kind will define the
region over which a membrane is attached to the flange of a capsule
body, and the channels 205 of a third kind defining where it is
unattached.
[0077] FIG. 2D depicts an attachment means provided with eight
faces 206 of a fourth kind, separated by eight channels 207 of a
fourth kind. Compared to the attachment means depicted in FIG. 2C,
the faces 206 of a fourth kind are much smaller than the faces 204
of a third kind, while the channels 207 of a fourth kind are much
larger than the channels 205 of a third kind. As a result, the
proportion of the flange of a capsule body to which a membrane will
be attached by the attachment device in FIG. 2D is much lower than
would be achieved by the attachment device of FIG. 2C, with a
corresponding increase in the size of the regions of the flange to
which the membrane remains unattached.
[0078] The attachment devices may in this way be configured to best
suit the particular application in which the attachment device is
to be employed. In the foregoing embodiments the attachment devices
are altered by adjusting their number and size; however, in other
embodiments it may be advantageous to modify other elements of
their form and geometry such as shape, thickness, or placement
about the lower end of the attachment means.
[0079] In this way, one may configure the attachment means to
reduce the time required to apply the vacuum to the capsule body
while still minimizing the aspiration and entrainment of the coffee
powder or other edible granules contained within the capsule body.
The sealing of the beverage capsules may thus be optimized to
achieve a maximum output at a minimum cost.
[0080] FIG. 3 is a flowchart depicting the method of packaging as
integrated into a process for the fabrication of beverage capsules,
said operation comprising a series of elements. The first step of
the operation is Capsule Body Destacking 300. The empty capsule
bodies are generally stored stacked atop each other when stored
before use, and so must be separated before they can be further
processed. In the step for Capsule Body Destacking 300, the capsule
bodies are separated from each other and placed in the proper
orientation to continue in the process.
[0081] Simultaneously, the Coffee Preparation Process 301 furnishes
a supply of coffee powder for packaging within the beverage
capsules. In the Coffee Preparation Process 301, coffee beans are
roasted to the desired degree of roasting and then ground to the
desired degree of fineness.
[0082] As discussed above, the gases generated within the coffee
beans during roasting are evolved from the coffee. Some degassing
will occur between the roasting of the coffee and the sealing of
the beverage capsule. In certain particular, non-limiting
embodiments, it is preferable, however, to configure the process
for fabrication of beverage capsules to minimize degassing outside
of the capsule, so that the degassing essentially occurs after the
beverage capsule has been sealed. In an embodiment, the duration
between the grinding of the coffee and the sealing of the capsule
is less than ten minutes.
[0083] By limiting degassing before sealing, the aroma and flavor
in the capsule are best preserved. After several days, equilibrium
is reached between the emanated gases and the retained gases in the
coffee. This equilibrium depends on the ratio of the coffee weight
to the total volume in the capsule, the pressure reduction applied
during the vacuum step and the resistance of the capsule to the
equilibrium pressure.
[0084] Furthermore, since the coffee is not degassed before the
sealing process, the infrastructure required to degas the coffee
beforehand is no longer necessary. This renders the beverage
capsule sealing operation more compact, economical, and
flexible.
[0085] During Product Filling & Densifying 302, a portion of
the coffee powder provided by the Coffee Preparation Process 301 is
placed within the capsule body and densified, so that the coffee is
settled within the capsule body and the amount of gas therein is so
minimized. In an alternate embodiment, the beverage powder may be
compacted into a tablet during the Coffee Preparation Process 301
step, which is then positioned in the capsule body during the step
of Product Filling & Densifying 302.
[0086] Ideally, each element of the operation is linked by a step
for Transport 303, where the capsule body is transferred between
the devices for carrying out each element of the operation. In
addition, it is understood that the elements for carrying out each
of the elements of the process may be located in proximity to each
other, or even integrated into each other, so that the time
required for transporting the beverage capsule between elements is
minimized. The process is thereby rendered more space-efficient and
economical.
[0087] After this is Membrane Attachment and Cutting 305, as
depicted in Views A-D of FIG. 1. In this step, the membrane is
attached to the flange of the capsule body at a plurality of
regions of the flange, leaving a plurality of unsealed regions on
said flange as well. The membrane is also cut to a size which will
cover the flange and open end of the capsule body.
[0088] Following Membrane Attachment & Cutting 305 is Vacuum
Application & Sealing 306, depicted in FIG. 1, Views E-H. A
vacuum is applied to the capsule body, removing the air from within
through the plurality of unsealed regions of the flange. The
membrane is then sealed over the entirety of the surface of the
flange, preserving the vacuum within the capsule.
[0089] In beverage capsules containing roasted, ground coffee as
shown here, it is particularly advantageous that the vacuum within
the capsule is a reduction of pressure high enough to offset the
pressure generated by the gases evolved by the coffee as it
degasses in the capsule. A normally configured beverage capsule
will so resist the pressure accumulated within the sealed capsule
as a result of the evolved gases.
[0090] Finally, the capsule is transferred to Distribution 308,
where it may be packaged in a box, sleeve, bag, or the like and
distributed for sale.
[0091] FIG. 4 depicts a method for packaging a capsule 400
containing beverage powder tending to evolve a gas, in an
over-packaging. The method comprises providing a quantity of
beverage powder capable of evolving a gas within a cavity 406 of a
capsule body 403. The capsule body 403 is substantially cup-shaped
and is provided with an open end 408 communicating with said cavity
and a bottom end 401. The bottom end may be apertured. For example,
a plurality of small apertures can be present in the wall of the
bottom end 401 to facilitate (without need for a puncturing member)
the feeding of water and/or discharge of beverage during
extraction. The apertures are small enough to allow liquid transfer
but maintain powder in the cavity.
[0092] The capsule 400 may further comprise a flange 409 onto which
is sealed a lid such as a flexible membrane 412 (Step II). In
certain particular, non-limiting embodiments, the membrane material
is provided in the form of a continuous sheet or web. In an
alternative, the lid can be a rigid or semi-rigid wall member
connected to the flange by welding, e.g., heat or ultrasonic
welding, and/or press-fitting in the cavity. The lid may be formed
of a material hermetical to gas and sealed hermetically on the
flange. However, it may also be non-hermetic to gas and liquid. For
example, the lid may be apertured. A plurality of small apertures
can be present in the lid to facilitate (without need for a
puncturing member) the feeding of water and/or discharge of
beverage during extraction. The apertures are small enough to allow
liquid transfer but maintain powder in the cavity.
[0093] In this embodiment, the capsule 400 is sealed in an
over-packaging 500 (Step III). The over-packaging may be a flexible
or rigid package. For example, it can be a flow wrap package sealed
onto a seam 501. A vacuum is drawn before and during sealing of the
over-packaging in the interior of the over-packaging. Since the
capsule 400 is permeable to gas, a vacuum is formed in the cavity
as well. A pressure equilibrium is rapidly obtained so that the
pressure in the cavity is the same as the pressure between the
capsule 400 and the over-packaging 500.
[0094] As in the previous embodiment, the gases generated within
the coffee beans during roasting are evolved from the coffee. Some
degassing will occur between the roasting and the sealing of the
over-packaging. In certain particular, non-limiting embodiments,
the process is configured for fabrication of the packed beverage
capsule to minimize degassing before sealing, so that the degassing
essentially occurs after the beverage capsule has been sealed in
the over-packaging (Step IV). As a result of the gas emanating in
the capsule and traversing the capsule, the pressure in the
over-packaging becomes above the atmospheric pressure. In this way
the flavor of the coffee is most effectively preserved. The
over-packaging is essentially impermeable to gas so that the
evolved gases after sealing is maintained in the over-packaging.
After several days, equilibrium is reached between the emanated
gases and the retained gases in the coffee. This equilibrium
depends on the ratio of the coffee weight to the total volume in
the over-packaging, the pressure reduction applied during the
vacuum step and the resistance of the over-packaging to the
equilibrium pressure.
[0095] In the context as described in the above description, the
hermetical closure to the gases refers to the ability of the
package, that is the capsule itself or the over-packaging, to
maintain an internal pressure above 1050 mbar for a period of at
least one week.
[0096] Of course, the presently disclosed and/or claimed inventive
concept(s) is not limited to the embodiments described above and in
the accompanying drawings. Modifications remain possible,
particularly as to the construction of the various elements or by
substitution of technical equivalents, without thereby departing
from the scope of protection of the presently disclosed and/or
claimed inventive concept(s).
[0097] In particular, it should be understood that the presently
disclosed and/or claimed inventive concept(s) may be adapted to
fabricate beverage capsules for the preparation of various kinds of
alimentary substances, for example broth, cocoa, coffee, infant
formula, milk, tea, tisane or any combination thereof. It should
also be understood that the edible granules comprising said
alimentary substances may be provided in various forms and sizes,
such as flakes, grains, granules, pellets, powders, or shreds and
any combinations thereof. While the particular embodiment of the
preceding description is directed to a beverage capsule containing
a quantity of roasted, powdered coffee, it should not be construed
as limiting the scope of the presently disclosed and/or claimed
inventive concept(s) to beverage capsules so configured.
[0098] The exact configuration and operation of the presently
disclosed and/or claimed inventive concept(s) as practiced may thus
vary from the foregoing description without departing from the
inventive principle described therein. Accordingly, the scope of
this disclosure is intended to be exemplary rather than limiting,
and the scope of the presently disclosed and/or claimed inventive
concept(s) is defined by any claims that stem at least in part from
it.
* * * * *