U.S. patent application number 15/109305 was filed with the patent office on 2016-11-17 for element of a capsule and capsule containing ground coffee ingredient.
The applicant listed for this patent is NESTEC S.A.. Invention is credited to Etienne CLOSSET, Abdenour DJAMER, Paul EICHLER, Christian GUENAT, Ulrich KESSLER, Patricia Ann Mathias, Frederic MESTDAGH, Celine SARRAZIN-HORISBERGER, Olivier VILLAIN.
Application Number | 20160332806 15/109305 |
Document ID | / |
Family ID | 49920168 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160332806 |
Kind Code |
A1 |
Mathias; Patricia Ann ; et
al. |
November 17, 2016 |
Element of a Capsule and Capsule Containing Ground Coffee
Ingredient
Abstract
A capsule element for a capsule comprising a ground coffee
ingredient, wherein the capsule element (21) comprises a rim (26)
for sealing engagement with a second capsule element, at least one
sidewall (22), and a bottom wall (23), wherein the at least one
side wall (22) and the bottom wall (23) define an interior chamber
(24) having an opening (25), the opening spanning a plane (P),
wherein further the rim (26) extends outwards from the sidewall
(22) and surrounds the opening (25), the rim being bent into the
direction of the bottom wall (23), the rim and the plane (P) of the
opening forming an angle (A) of at least about 10.degree.. The
invention also relates to a capsule comprising the capsule element
and a membrane hermetically sealed thereon.
Inventors: |
Mathias; Patricia Ann;
(Lithia, FL) ; DJAMER; Abdenour; (Lausanne,
CH) ; VILLAIN; Olivier; (Noville, CH) ;
GUENAT; Christian; (L'Auberson, CH) ;
SARRAZIN-HORISBERGER; Celine; (Suchy, CH) ; MESTDAGH;
Frederic; (Epalinges, CH) ; EICHLER; Paul;
(Singapore, SG) ; KESSLER; Ulrich; (Savigny,
CH) ; CLOSSET; Etienne; (Corcelles-Cormondreche,
CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NESTEC S.A. |
VEVEY |
|
CH |
|
|
Family ID: |
49920168 |
Appl. No.: |
15/109305 |
Filed: |
December 19, 2014 |
PCT Filed: |
December 19, 2014 |
PCT NO: |
PCT/EP2014/078706 |
371 Date: |
June 30, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 21/0209 20130101;
B65D 85/8043 20130101 |
International
Class: |
B65D 85/804 20060101
B65D085/804; B65D 21/02 20060101 B65D021/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 8, 2014 |
EP |
14150447.2 |
Claims
1. A first capsule element for a capsule comprising a ground coffee
ingredient, wherein the first capsule element comprises: a rim for
sealing engagement with a second capsule element, at least one
sidewall, a bottom wall, an interior chamber defined by the at
least one side wall and the bottom wall and having an opening, the
opening spanning a plane, wherein further the rim extends outwards
from the sidewall and surrounds the opening, the rim being bent
into the direction of the bottom wall, the rim and the plane of the
opening forming an angle of at least about 10.degree..
2. The first capsule element according to claim 1, wherein the
angle is at least about 12.degree..
3. The first capsule element according to claim 1, wherein the
angle is from about 12.degree. to about 26.degree..
4. The first capsule element according to claim 1, wherein the
sidewall has an upper and a lower end, the upper end defining a
circle having a first diameter, the lower end defining a circle
having a second diameter, wherein the opening is located at the
upper end, and optionally wherein the second diameter is smaller
than the first diameter.
5. The first capsule element according to claim 1, wherein the
first capsule element forms a capsule body.
6. The first capsule element according to claim 1, wherein the
first capsule element is rotationally symmetric.
7. The first capsule element according to claim 1, wherein the
first capsule element is essentially gas-tight.
8. A capsule comprising: the first capsule element according to any
one of claims 1 to 7, and a second capsule element for sealing
connection with the rim of the first capsule element, and
optionally wherein the second capsule element is in sealing
connection with the rim.
9. The capsule according to claim 8, wherein the sealing connection
of the second capsule element with the rim extends from the inner
sealing point to the outer sealing point along a rectilinear
direction when the capsule is viewed in cross-sectional view.
10. The capsule according to claim 8, wherein the second capsule
element is a membrane.
11. The capsule according to claim 10, wherein the membrane has a
thickness of from about 30 .mu.m to about 40 .mu.m.
12. The capsule according to claim 10, wherein the membrane is
impermeable for CO.sub.2.
13. The capsule according to claim 12, wherein the membrane is an
aluminium membrane or a multilayer of aluminium and polymer.
14. The capsule according to claim 8, wherein the capsule is a
hermetically or gas-tightly sealed capsule.
15. The capsule according to claim 8, wherein the pressure in the
capsule is from about 300 mbar to about 500 mbar.
16. The capsule according to claim 8, wherein the capsule comprises
a coffee ingredient.
17. The first capsule element according to claim 3, wherein the
angle is: from about 14.degree. to about 24.degree.; from about
16.degree. to about 22.degree.; and/or from about 18.degree. to
about 20.degree..
18. The first capsule element of claim 6, wherein the first capsule
element is essentially frusto-conical in shape.
19. The first capsule element of claim 7, wherein the first capsule
element is made of aluminium or a polymer composition comprising a
gas barrier or a laminate of polymer and aluminium.
20. The capsule according to claim 12, wherein the membrane is
gas-tight.
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/EP2014/078706, filed Dec. 19, 2014; which claims priority to
Application No. EP 14150447.2, filed Jan. 8, 2014. The entire
contents of the above-referenced application are hereby expressly
incorporated herein by reference.
BACKGROUND
[0002] The presently disclosed and/or claimed inventive concept(s)
generally relates to processes for the preparation of coffee
ingredients and to capsules comprising these coffee ingredients.
The presently disclosed and/or claimed inventive concept(s) also
relates to capsule elements and capsules containing coffee
ingredients. In particular, the presently disclosed and/or claimed
inventive concept(s) relates to a sealed capsule particularly
designed to resist to delamination and/or breakage, thereby
allowing coffee gas to emanate in the sealed capsule and generating
a positive pressure without risk of damage of the capsule.
[0003] WO2010116284A2 relates to a brewing device and capsule for
preparing a drink such as coffee. The capsule comprises a hollow
element, an extraction membrane and an annular flange. The flange
comprises a recess in the form of annular groove positioned on the
side of the lower face of the flange; such recess communicating
with the interior of the capsule. One objective is to minimize the
risk of accidental delamination between the membrane and the flange
when the capsule is stored. In fact, the membrane is initially
glued to the full surface of the flange but when the force or
pressure exerted on the membrane is too high, such as during coffee
degasing, a wedge effect is produced between the first portion of
the flange and the membrane which allows the membrane to be
retained on the first portion. If the force or pressure reaches a
certain threshold, the membrane is unglued at the recess which
causes the total internal volume of the capsule to increase and the
pressure in the capsule to reduce. However, still delamination of
the membrane can occur. If the reserve of gas provided by the
recess is insufficient, the delamination will continue and cause
leakage. Furthermore, it is very difficult to control the volume of
the recess needed as a function of the coffee pressure release as
such release can depend from many different factors such as coffee
weight, roasting degree, coffee origin, etc. In addition, the
capsule is made relatively more complex.
[0004] The presently disclosed and/or claimed inventive concept(s)
alleviates the drawbacks of the prior art, as well as, provides new
advantages and benefits.
[0005] More generally, during the processing and storage of coffee
ingredients a partial loss of volatile substances (VSs), such as
volatile organic compounds (VOCs), occurs. A reduction in the
content of VSs is undesirable, since it results in a reduced
quality of the obtained product. The reduction of VSs has been
partially attributed to the influence of heat in the processing of
the coffee ingredients.
[0006] For example, coffee is typically processed by first roasting
the coffee beans. The roasted coffee then is allowed to rest so as
to slowly cool down, and afterwards is subjected to grinding. 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. 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.
Grinding the roasted coffee beans will accelerate this process.
[0007] A significant loss of VSs can occur during the further
processing steps and in particular during grinding.
[0008] Therefore, it has been suggested to keep the coffee cool
during further processing steps. Likewise, it has been suggested to
store the obtained product in the cold.
[0009] However, despite these efforts, loss of VSs occurs,
resulting in a reduced aroma of the obtained product and often also
in further deterioration during storage.
[0010] It is therefore desirable to provide improved processes for
the preparation of coffee ingredients, in particular of ground
coffee, which allow the reduction of the loss of VSs from the
ingredient. It is also desirable to provide improved means for use
in relation with these processes and for improved processed
ingredients.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 shows a non-limiting block diagram depicting
essential and optional steps of a process according to the
presently disclosed and/or claimed inventive concept(s).
[0012] FIG. 2 shows a non-limiting block diagram depicting
essential and optional steps of a process according to the
presently disclosed and/or claimed inventive concept(s).
[0013] FIG. 3 shows non-limiting schematic drawings of a capsule
according to the presently disclosed and/or claimed inventive
concept(s).
[0014] FIGS. 4 to 6 show results of determining sensory profiles of
capsules.
[0015] FIGS. 7 to 8 show results of experiments analyzing the
impact of the capsule rim angle.
DETAILED DESCRIPTION
[0016] Accordingly, the presently disclosed and/or claimed
inventive concept(s) provides a process of preparing a capsule
comprising a ground coffee ingredient, the process comprising the
steps of: (a) cooling a coffee ingredient, in particular coffee
beans, to a temperature of about -50.degree. C. to about 10.degree.
C.; (b) grinding the coffee ingredient, in particular coffee beans,
optionally wherein the coffee ingredient is cooled during grinding;
(c) filling the ground coffee ingredient into a first capsule
element, optionally wherein the coffee ingredient is cooled during
filling; and (d) hermetically sealing the first capsule element
with a second capsule element, optionally wherein the coffee
ingredient is cooled during sealing.
[0017] The process can comprise the preliminary step of: (a)'
roasting the coffee ingredient, in particular, coffee beans. Step
(a)' can be performed prior to step (a).
[0018] The process can comprise the step of: (a)'' tempering the
coffee ingredient, in particular, the roasted coffee beans. Step
(a)'' can be performed prior to step (a). Step (a)'' can be
performed after step (a)' and prior to step (a).
[0019] The process can comprise the step of: (c)' compressing the
coffee ingredient, optionally wherein the coffee ingredient is
cooled during compressing. Step (c)' can be performed after step
(b) and prior to step (c).
[0020] The process can comprise the step of: (c)'' degasification
of the coffee ingredient, optionally wherein the coffee ingredient
is cooled during degasification. Step (c)'' can be performed after
step (b) and prior to step (c). Step (c)'' can be performed after
step (c)' and prior to step (c). In certain non-limiting
embodiments, degasification is kept short to enable a partial loss
of the gas contained in the coffee ingredient.
[0021] Degasification in step (c)'' can be performed for about 120
min or less, for about 60 min or less, for about 35 min or less,
for about 25 min or less, for about 20 min or less, for about 15
min or less, for about 10 min or less, or for about 5 min or
less.
[0022] According to some embodiments, the process does not comprise
a degasification step (c)'', or does not comprise any
degasification step.
[0023] In step (a), the coffee ingredient can be cooled to a
temperature of about -50.degree. C. to about 5.degree. C., about
-45.degree. C. to about 5.degree. C., about -40.degree. C. to about
0.degree. C., about -35.degree. C. to about -5.degree. C., about
-30.degree. C. to about -10.degree. C., about -25.degree. C. to
about -15.degree. C., or about -20.degree. C.
[0024] The coffee ingredient can be maintained at a temperature of
about -50.degree. C. to about 10.degree. C. in step (b). The coffee
ingredient can be maintained at a temperature of about -50.degree.
C. to about 10.degree. C. in step (c). The coffee ingredient can be
maintained at a temperature of about -50.degree. C. to about
10.degree. C. in step (c)'. The coffee ingredient can be maintained
at a temperature of about -50.degree. C. to about 10.degree. C. in
step (c)''. The coffee ingredient can be maintained at a
temperature of about -50.degree. C. to about 10.degree. C. in step
(d).
[0025] The coffee ingredient can be maintained at a temperature of
about -50.degree. C. to about 10.degree. C. in step (b) and/or in
step (c) and/or in step (c)' and/or in step (c)'' and/or in step
(d). The coffee ingredient can be maintained at a temperature of
about -45.degree. C. to about 5.degree. C., about -40.degree. C. to
about 0.degree. C., about -35.degree. C. to about -5.degree. C.,
about -30.degree. C. to about -10.degree. C., about -25.degree. C.
to about -15.degree. C., or about -20.degree. C. in one or more,
including (but not limited to) all, of these steps. The temperature
can be selected independently for each step.
[0026] The first capsule element can comprise a rim for sealing
engagement with the second capsule element, at least one sidewall,
and a bottom wall, wherein the at least one side wall and the
bottom wall define an interior chamber having an opening, the
opening spanning a plane, wherein further the rim extends outwards
from the sidewall and surrounds the opening, the rim being bent
into the direction of the bottom wall, the rim and the plane of the
opening forming an angle of at least about 10, such as (but not
limited to) at least about 12.degree..
[0027] The angle can be about 10.degree. to about 31.degree., such
as about 12.degree. to about 28.degree., about 12.degree. to about
26.degree., about 14.degree. to about 24.degree., about 16.degree.
to about 22.degree., or about 18.degree. to about 20.degree.. The
angle can be 10.degree., 11.degree., 12.degree., 13.degree.,
14.degree., 15.degree., 16.degree., 17.degree., 18.degree.,
19.degree., 20.degree., 21.degree., 22.degree., 23.degree.,
24.degree., 25.degree., 26.degree., 27.degree., 28.degree.,
29.degree., or 30.degree.. In certain non-limiting embodiments, the
angle is about 12.degree. to about 28.degree., such as about
16.degree. to about 28.degree., or about 18.degree. to about
26.degree., or of about 20.degree. to about 28.degree., such as
(but not limited to) about 22.degree. to about 26.degree., or about
24.degree..
[0028] As will be explained later on, the angle provides a higher
resistance of the second element sealed onto the first element to
delamination and/or breakage and so allows the gas to emanate in
the sealed capsule and generate a positive pressure without risk of
damage of the capsule.
[0029] A vacuum or a reduced pressure can be applied to the first
capsule element after filling the ground coffee ingredient into the
first capsule element and before the first capsule element is
hermetically sealed with the second capsule element.
[0030] The reduced pressure applied to the first capsule element
can be about 100 mbar to about 800 mbar under atmospheric
pressure.
[0031] The first capsule element can be a capsule body. The first
capsule element can be rotationally symmetric. The first capsule
element can be of essentially frusto-conical shape or of
frusto-conical shape.
[0032] The second capsule element can be a membrane. The membrane
can have a thickness of about 30 .mu.m to about 40 .mu.m. The
membrane can be impermeable for CO.sub.2. In certain non-limiting
embodiments, the membrane is gas-tight.
[0033] In certain particular non-limiting embodiments, the coffee
ingredient is roasted coffee.
[0034] The presently disclosed and/or claimed inventive concept(s)
also provides a capsule obtainable by the process according to the
presently disclosed and/or claimed inventive concept(s).
[0035] The presently disclosed and/or claimed inventive concept(s)
further provides a capsule element for a capsule comprising a
ground coffee ingredient, wherein the capsule element comprises a
rim for sealing engagement with a second capsule element, at least
one sidewall, and a bottom wall, wherein the at least one side wall
and the bottom wall define an interior chamber having an opening,
the opening spanning a plane, wherein further the rim extends
outwards from the sidewall and surrounds the opening, the rim being
bent into the direction of the bottom wall, the rim and the plane
of the opening forming an angle of at least about 10.degree., such
as (but not limited to) at least about 12.degree..
[0036] The angle can be about 10.degree. to about 31.degree., such
as about 10.degree. to about 28.degree., such as about 12.degree.
to about 26.degree., about 14.degree. to about 24.degree., about
16.degree. to about 22.degree., or about 18.degree. to about
20.degree..
[0037] The sidewall can have an upper and a lower end, the upper
end defining a circle having a first diameter, the lower end
defining a circle having a second diameter, wherein the opening is
located at upper end, optionally wherein the second diameter is
smaller than the first diameter. The bottom wall can be located at
the lower end. The bottom wall can be located opposite the
opening.
[0038] The first capsule element can be a capsule body. The first
capsule element can be rotationally symmetric. The first capsule
element can be of essentially frusto-conical shape or of
frusto-conical shape.
[0039] Also, the presently disclosed and/or claimed inventive
concept(s) provides for a capsule comprising as a first capsule
element a capsule element as described above, the capsule further
comprising a second capsule element for sealing connection with the
rim of the first capsule element.
[0040] The second capsule element can be in sealing connection with
the rim.
[0041] The second capsule element can be a membrane. The membrane
can have a thickness of about 30 .mu.m to about 40 .mu.m. The
membrane can be impermeable for carbon gas (CO2, CO) and aroma
volatiles. In certain non-limiting embodiments, the membrane is
gas-tight.
[0042] The capsule can comprise a coffee ingredient, such as (but
not limited to) roast and ground coffee.
[0043] The presently disclosed and/or claimed inventive concept(s)
and its advantages are now described in more detail. It is
understood that the examples and drawings provided herein serve to
illustrate aspects of the presently disclosed and/or claimed
inventive concept(s), however are not to be construed as limiting
to the scope of the presently disclosed and/or claimed inventive
concept(s). Likewise, headlines used in this section are provided
for the convenience of the reader, however are not to be construed
as limiting.
[0044] The expression "about", as used herein, is intended to
signify a range of .+-.10% or less, such as (but not limited to) in
a range of .+-.5% or less, of a given value.
[0045] Processes According to the Presently Disclosed and/or
Claimed Inventive Concept(s)
[0046] The presently disclosed and/or claimed inventive concept(s)
proposes to improve the aromatic features of the coffee in the
capsule so that a higher in-cup and/or above-cup aroma intensity of
the coffee extract can obtained. Accordingly, the presently
disclosed and/or claimed inventive concept(s) proposes to reduce
the loss of aroma volatiles during the processing of coffee
ingredients, such as coffee, by cooling the coffee ingredient, and
in certain non-limiting embodiments by ensuring the maintenance of
a cold environment during further processing steps such as
grinding, optional compacting and optional (reduced)
degasification, and eventually filling and capsule sealing such as
(but not limited to) under vacuum.
[0047] The processes according to the presently disclosed and/or
claimed inventive concept(s) allow reducing the loss of VSs, such
as VOCs, and also allow to reduce oxidation processes occurring
during processing and subsequent storage of the processed coffee
ingredient. This is reflected in an improved aroma of the obtained
product.
[0048] The present inventors have found that surprisingly, loss of
VSs, such as VOCs, in the processing of coffee ingredients (in
particular of coffee), can be significantly reduced when at least a
part of the processing is performed under cold conditions, applying
the specific process parameters described herein.
[0049] Accordingly, the aroma quality of coffee was found to be
significantly increased when processed according to a process of
the presently disclosed and/or claimed inventive concept(s),
especially when the aroma above the cup and in the cup was compared
to products of the prior art.
[0050] Moreover, the quality of the obtained ground coffee product
was found to be considerably improved when the product was filled
after reduced degasification into a dedicated capsule and the
capsule subsequently was hermetically sealed.
[0051] Accordingly, in one aspect the presently disclosed and/or
claimed inventive concept(s) provides a process of preparing a
capsule comprising a ground coffee ingredient.
[0052] The coffee ingredient filled in the capsule can be any
coffee ingredient that can be provided in a form such as (but not
limited to) roast and ground form. However, in particular,
non-limiting embodiments of the disclosure of the presently
disclosed and/or claimed inventive concept(s) throughout that the
coffee ingredient is coffee in any suitable form, such as in the
form of coffee beans, for example roasted coffee beans.
[0053] Thus, the coffee ingredient subjected to the process of the
presently disclosed and/or claimed inventive concept(s) can be
coffee, for example coffee beans, which may be roasted coffee
beans.
[0054] The capsule can be any capsule suitable for filling with
coffee ingredients, in particular ground coffee ingredients.
Typically, the capsule comprises a first capsule element and a
second capsule element. In certain non-limiting embodiments, the
capsule is sealable, such as (but not limited to) hermetically
sealable. According to a particular, non-limiting embodiment, the
capsule is sealable, or is hermetically sealable, by sealing
engagement of the first and second capsule elements. The first and
second capsule elements can be the same, or can be different from
each other. In certain particular, non-limiting embodiments, it may
also be desired that the capsule material or materials exhibit very
low gas permeability, or no gas permeability at all. In certain
particular, non-limiting embodiments, the capsule is substantially
gas tight, or is gas tight, once sealed or hermetically sealed.
Also, it is very desirable that the capsule is adapted to withstand
comparably high internal pressure, such as an internal pressure of
about 300 mbar to about 500 mbar, about 325 mbar to about 475 mbar,
about 350 mbar to about 450 mbar, about 375 mbar to about 425 mbar
or about 400 mbar. Especially, the pressure is due to the
degasification of the coffee ingredient after sealing of the
capsule. Also, in certain non-limiting embodiments it may be
desired that the capsule is adapted for insertion into a beverage
production device. In certain non-limiting embodiments, the capsule
is adapted to withstand an internal pressure of at least about 350
mbar, at least about 400 mbar, or at least about 450 mbar, such as
(but not limited to) about 400 mbar to about 500 mbar, or about 450
mbar to about 500 mbar. A capsule may be adapted to withstand
internal pressure if it remains intact, e.g. hermetically sealed,
at said pressure.
[0055] The capsule can comprise or can be made of any suitable
material such as, but not limited to, aluminium or a polymer
composition or a combination thereof. The polymer composition can
be polypropylene or polyethylene. Aluminium is a desired (but
non-limiting) material. In certain non-limiting embodiments, the
first element is essentially gas-tight, such as (but not limited
to) made of aluminium or a polymer composition comprising a gas
barrier, or a laminate of polymer and aluminium.
[0056] Further desirable features and properties of the capsule
elements and capsules will be described below.
[0057] In step (a) of the process, a coffee ingredient is cooled to
a temperature of about -50.degree. C. to about 10.degree. C.
[0058] The coffee ingredient can be cooled to a temperature of
about -45.degree. C. to about 5.degree. C., about -40.degree. C. to
about 0.degree. C., about -35.degree. C. to about -5.degree. C.,
about -30.degree. C. to about -10.degree. C., about -25.degree. C.
to about -15.degree. C., or about -20.degree. C. In certain
non-limiting embodiments, the coffee ingredient is cooled to a
temperature of about -30.degree. C. to about -10.degree. C., such
as (but not limited to) of about -25.degree. C. to about
-15.degree. C., or about -20.degree. C.
[0059] Cooling step (a) can be performed so that the coffee
ingredient is cooled to the desired temperature comparably fast,
for example within about 30 min or less, within about 20 min or
less, within about 10 min or less, or within about 5 min or less,
from the onset of cooling.
[0060] If the cooling step (a) is preceded by a roasting and/or
tempering step, in certain non-limiting embodiments, it may be
desired that the cooling step is carried out quickly (for example,
within about 60 min or less, within about 40 min or less, within
about 20 min or less, within about 10 min or less, or within about
5 min or less) after the end of the roasting step or tempering
step.
[0061] However if desired, the coffee ingredient can be stored for
a certain amount of time after cooling down and prior to grinding
step (b). The storing can be at a temperature of about -50.degree.
C. to about 10.degree. C., for example at about -45.degree. C. to
about 5.degree. C., about -40.degree. C. to about 0.degree. C.,
about -35.degree. C. to about -5.degree. C., about -30.degree. C.
to about -10.degree. C., such as (but not limited to) at about
-25.degree. C. to about -15.degree. C., or about -20.degree. C.
Storage at temperatures of about -5.degree. C. to about 10.degree.
C., such as about -3.degree. C. to about 8.degree. C., about
2.degree. C. to about 7.degree. C., or about 5.degree. C. is
likewise contemplated. The coffee ingredient can for example be
stored for at least about one hour, at least about two hours, at
least about five hours or from about one hour to about 24 hours.
After the cooling step, for example due to operational constraints
in case of line stoppage, the cold beans may be kept stored before
grinding between 0 minutes (=no line stoppage) up to 5 min, up to
30 min, up to 1 hour depending the unplanned time stoppage. So that
when the line restart after stoppage, the cold beans are fed into
the grinder at the right temperature.
[0062] In the alternative, the grinding step (b) can be performed
after cooling step (a) without storing the coffee ingredient after
cooling step (a).
[0063] In grinding step (b) of the process, which is typically
carried out after cooling step (a), the coffee ingredient is
ground.
[0064] Grinding typically is accompanied by the development of heat
(typically due to the mechanical forces generated by the mill and
coffee). Thus, in certain non-limiting embodiments, the coffee
ingredient is cooled during grinding. The coffee ingredient can be
cooled to or maintained at a temperature of about -50.degree. C. to
about 10.degree. C., about -45.degree. C. to about 5.degree. C.,
about -40.degree. C. to about 0.degree. C., about -35.degree. C. to
about -5.degree. C., about -30.degree. C. to about -10.degree. C.,
about -25.degree. C. to about -15.degree. C., or about -20.degree.
C. Particular non-limiting examples are temperatures of about
-5.degree. C. to about 10.degree. C., such as about -3.degree. C.
to about 8.degree. C., or about 2.degree. C. to about 7.degree. C.,
or about 5.degree. C. Other non-limiting examples include a
temperature of about -25.degree. C. to about -15.degree. C., or
about -20.degree. C.
[0065] Filling step (c) of the process is typically performed after
grinding step (b). In this step, the coffee ingredient is filled
into a first capsule element. Again, in certain non-limiting
embodiments, it may be desired that the coffee ingredient is cooled
during this step, to avoid loss of VSs. Accordingly, the coffee
ingredient can be cooled to or maintained at a temperature of about
-50.degree. C. to about 10.degree. C., about -45.degree. C. to
about 5.degree. C., about -40.degree. C. to about 0.degree. C.,
about -35.degree. C. to about -5.degree. C., about -30.degree. C.
to about -10.degree. C., about -25.degree. C. to about -15.degree.
C., or about -20.degree. C. in step (c). Particular non-limiting
examples are temperatures of about -5.degree. C. to about
10.degree. C., such as about -3.degree. C. to about 8.degree. C.,
or about 2.degree. C. to about 7.degree. C., or about 5.degree. C.
Other non-limiting examples include a temperature of about
-25.degree. C. to about -15.degree. C., or about -20.degree. C.
[0066] In a further step, step (d), the first capsule element is
hermetically sealed with a second capsule element. As a result, the
first and second capsule elements are connected with one another
and may form a completely closed capsule. The connection formed by
hermetically sealing may be complete and substantially air tight,
or air tight. In certain particular non-limiting embodiments, the
connection is gas tight. The hermetically sealing may comprise
welding and/or crimping.
[0067] Again, in certain non-limiting embodiments, it may be
desired that the coffee ingredient is cooled during this step.
Thus, the coffee ingredient can be cooled to or maintained at a
temperature of about -50.degree. C. to about 10.degree. C., about
-45.degree. C. to about 5.degree. C., about -40.degree. C. to about
0.degree. C., about -35.degree. C. to about -5.degree. C., about
-30.degree. C. to about -10.degree. C., about -25.degree. C. to
about -15.degree. C., or about -20.degree. C. in step (d).
Particular non-limiting examples are temperatures of about
-5.degree. C. to about 10.degree. C., such as about -3.degree. C.
to about 8.degree. C., or about 2.degree. C. to about 7.degree. C.,
about 5.degree. C. Other non-limiting examples include a
temperature of about -25.degree. C. to about -15.degree. C., or
about -20.degree. C.
[0068] Albeit not required, the process may comprise one or more
additional steps.
[0069] For example, the process may further comprise step (a)', in
which the coffee ingredient is roasted. The conditions applied
during roasting are not particularly limited and may be as known in
the art. If the process encompasses roasting step (a)', step (a)'
is performed prior to step (a).
[0070] In other words, according to some embodiments, step (a) may
not be the initial step of the process according to the presently
disclosed and/or claimed inventive concept(s).
[0071] In the alternative or in addition, the process may further
comprise step (a)'', in which tempering of the coffee ingredient is
performed. Tempering aims at homogenising the water content of the
coffee ingredient. It can be performed by storing the coffee
ingredient for a given amount of time (such as of 60 to 80 minutes)
generally under ambient temperature and under modified atmosphere
(e.g. saturated with nitrogen gas).
[0072] If the process comprises tempering step (a)'', said step is
performed prior to step (a). In embodiments where the process
encompasses both, step (a)' and step (a)'', step (a)'' can be
performed after step (a)' and prior to step (a).
[0073] In the alternative or in addition, the process may further
comprise step (c)', wherein the coffee ingredient is compressed or
normalized. Generally, the coffee ingredient is beaten or
mixed/homogenised to obtain the right density (e.g., 420 g/L for
5.5 g of coffee ingredient) and then the capsule is filled in with
the right weight of coffee ingredient.
[0074] Again, it is desirable that the coffee ingredient is cooled
during this step. Accordingly, the coffee ingredient can be cooled
to or maintained at a temperature of about -50.degree. C. to about
10.degree. C., about -45.degree. C. to about 5.degree. C., about
-40.degree. C. to about 0.degree. C., about -35.degree. C. to about
-5.degree. C., about -30.degree. C. to about -10.degree. C., about
-25.degree. C. to about -15.degree. C., or about -20.degree. C. in
step (c)'. Particular non-limiting examples are temperatures of
about -5.degree. C. to about 10.degree. C., such as about
-3.degree. C. to about 8.degree. C., or about 2.degree. C. to about
7.degree. C., or about 5.degree. C. Other non-limiting examples
include a temperature of about -25.degree. C. to about -15.degree.
C., or about -20.degree. C.
[0075] Typically, step (c)' is performed after step (b) and prior
to step (c).
[0076] Certain coffee ingredients, such as for example coffee, are
typically processed by methods that encompass a degasification
step, in particular after the coffee ingredient has been ground.
Due to the enlarged ingredient surface formed as a result of
grinding, degasification is typically allowed for after grinding.
During degasification, the emission of carbon gas (CO.sub.2 and CO)
developing due to the roasting process from ground coffee
ingredient is allowed for.
[0077] Accordingly, in the alternative or in addition, the process
according to the presently disclosed and/or claimed inventive
concept(s) may further comprise step (c)'', degasification of the
coffee ingredient. Step (c)'' can be performed after step (b) and
prior to step (c), or after step (c)' and prior to step (c).
[0078] It should be noted that according to typical methods of the
prior art, the degasification step is performed at ambient
temperature and requires considerable amounts of time, and may take
up to 72 hours or even longer. However, the prior art has paid
little attention to the significance of this step in relation with
oxidation processes and loss of VSs from the coffee product.
[0079] The present inventors found the quality of the obtained
coffee product to be even further improved when the time between
the end of the grinding step and the hermetically sealing of the
capsule was reduced. Accordingly, in a particular, non-limiting
embodiment of the process according to the presently disclosed
and/or claimed inventive concept(s), the time between the end of
the grinding step and the hermetically sealing of the capsule is
reduced, e.g. is reduced to less than about 180 min, less than
about 150 min, less than about 120 min, less than about 90 min,
less than about 60 min, less than about 45 min, less than about 30
min or even less than 20 min.
[0080] In particular, the present inventors have also found that a
reduction in the duration of the degasification step (c)''
advantageously reflects on the quality of the obtained product,
since oxidization processes and loss of VSs, such as VOCs, is
reduced. Without wishing to be bound by theory, the inventors have
found that the carbon gas (CO.sub.2, CO) emitted from the coffee
ingredient during the degasification step comprises large amounts
of VSs. The reduction of the processing times from the end of the
grinding step to the hermetically sealing of the capsule was found
to significantly decrease the loss of VSs due to emission of carbon
gas. A reduction in the duration of the degasification step itself
has been found particular useful, especially when combined with
maintaining the coffee product at comparably cool temperatures
during the degasification step.
[0081] Accordingly, in certain non-limiting embodiments, it may be
desired that the degasification step (c)'', if present, is
performed for about 40 min or less, for about 35 min or less, for
about 30 min or less, for about 25 min or less, for about 20 min or
less, for about 15 min or less, for about 10 min or less, or for
about 5 min or less. In certain non-limiting embodiments, the
duration of step (c)'' is about 35 min to about 5 min, such as (but
not limited to) about 20 min to about 10 min.
[0082] Likewise, it has been found that cooling the coffee
ingredient during degasification further helps to retain VSs and to
reduce oxidation processes. Accordingly, in certain non-limiting
embodiments, it may be desired that the coffee ingredient in step
(c)'' is cooled. In certain particular non-limiting embodiments,
the coffee ingredient is cooled to or maintained at a temperature
of about -50.degree. C. to about 10.degree. C., about -45.degree.
C. to about 5.degree. C., about -40.degree. C. to about 0.degree.
C., about -35.degree. C. to about -5.degree. C., about -30.degree.
C. to about -10.degree. C., about -25.degree. C. to about
-15.degree. C., or about -20.degree. C. in step (c)''. Particular
non-limiting examples are temperatures of about -5.degree. C. to
about 10.degree. C., such as about -3.degree. C. to about 8.degree.
C., or about 2.degree. C. to about 7.degree. C., or about 5.degree.
C. Other non-limiting examples include a temperature of about
-25.degree. C. to about -15.degree. C., or about -20.degree. C.
[0083] Reduction in duration of step (c)'' and cooling, as detailed
above, can advantageously be applied in combination.
[0084] As already indicated above, the coffee ingredient can be
cooled in one or more steps of the process according to the
presently disclosed and/or claimed inventive concept(s). Also, the
coffee ingredient can be maintained at a certain temperature in one
or more steps of the process according to the presently disclosed
and/or claimed inventive concept(s). While apart from cooling step
(a), cooling is not required; however, it may be desired in certain
non-limiting embodiments that the coffee ingredient is cooled in at
least one of steps (b), (c), (d), and--insofar as present--(c)' and
(c)''. In certain particular non-limiting embodiments, the coffee
ingredient is cooled in all of these steps. In even more particular
non-limiting embodiments, the coffee ingredient is maintained at a
temperature of about -50.degree. C. to about 10.degree. C. in at
least one of steps (b), (c), (d), and--insofar as present--(c)' and
(c)''. In certain particular non-limiting embodiments, the coffee
ingredient is maintained at a temperature of about -50.degree. C.
to about 10.degree. C. in all of these steps. The temperature may
be chosen independently for each step.
[0085] Means for cooling and/or maintaining a coffee ingredient at
a desired temperature that can be applied in the process according
to the presently disclosed and/or claimed inventive concept(s) are
readily available to the skilled person. For example, and without
limitation, cooling and/or maintaining of the coffee ingredient at
the desired temperature can be achieved by cold inert substances,
such as liquid nitrogen or solid carbon dioxide. These substances
can be brought in direct contact with the coffee ingredient, or can
be provided in a closed system that is in contact with or in
proximity to the coffee ingredient. A fan or similar equipment can
be used to remove evaporating gas, such as evaporating liquid
nitrogen, from the coffee ingredient or the system if desired.
[0086] In the alternative or in addition, freezing devices can be
used, such as blast freezers, spiral freezers or tunnel freezers.
Likewise, cooling units such as water cooling units can be used.
Also, cooling can be achieved by circulation of a cold fluid inside
double jacketed equipment. A cooling fluid can be circulated in the
water circuit of the grinder, the normalizer used for compacting
and/or the degasing unit.
[0087] While cold temperatures during the degasification step and
reduction of the degasification time were found to work well, best
effects where obtained when the degasification step was omitted
entirely from the process according to the presently disclosed
and/or claimed inventive concept(s). Thus, according to one aspect,
the present process does not comprise a long degasification step
(c)'', or does not comprise any degasification step (i.e. neither
comprises a step (c)'' as detailed above nor any other dedicated
degasification step).
[0088] Besides advantages relating to the quality of the obtained
product, reduced processing times improve the efficacy of the
entire process. Thus, reduced processing times, in particular
reducing the duration of the degasification step or omitting said
step entirely, offer clear advantages, especially when combined
with maintaining the coffee product at comparably cool temperatures
during some or all steps of the process.
[0089] Yet, emission of carbon gas from the coffee ingredient
during filling, sealing and even thereafter, is a further effect of
the reduced processing times that is particularly pronounced if the
time allowed for the degasification step is reduced, degasification
is carried out while maintaining the product at cold temperatures,
or the process does not comprise any degasification step at
all.
[0090] On the one hand, the emitted gas advantageously helps to
further reduce oxidation processes that may occur in the coffee
ingredient, because the contact of the oxygen comprised in the
surrounding atmosphere with the coffee ingredient is minimized and
the emitted gas builds a less oxidizing atmosphere in the sealed
capsule. This may abolish the need for inert gas to create a
non-oxidizing atmosphere during processing steps and also within
the capsule. Yet, inert gas, such as nitrogen, can nevertheless be
used if desired.
[0091] On the other hand however, the emission of gas in the sealed
capsule may result in an elevated pressure within the capsule,
especially if the capsule is hermetically sealed. However,
hermetically sealing of the capsule is highly desirable to avoid
the eventual loss of VSs along with CO.sub.2 escaping from the
capsule, to avoid the exposure to oxygen entering the capsule and
for general hygiene considerations.
[0092] The elevated pressure occurring is especially problematic in
capsules adapted for insertion into and/or use with a beverage
production device. Many of these devices rely on the interaction of
a coffee ingredient provided in a capsule with a liquid, such as
hot water, that enters the capsule under pressure, for example
through a slit or the like in the capsule created in the beverage
production device. To retrieve the liquid from the capsule, the
capsule is typically adapted to allow for the opening of the
capsule upon injection of a pressurized liquid during machine
extraction, e.g. by tearing or disruption of a capsule element,
such as a membrane.
[0093] Generally, since the capsule comprises a capsule element,
such as a membrane, intended to be torn under liquid pressure in
the machine during extraction, the capsule element can burst and
break or delaminate if a too high pressure of gas is created in the
capsule during storage. This can be the case if a coffee
ingredient, such as coffee is not or not sufficiently degased
before the filling and sealing steps and therefore coffee produces
gas in the sealed capsule.
[0094] The possibilities of making such a capsule more pressure
resistant by simply providing a thicker and/or stronger material
are limited, because otherwise, the capsule would no longer open
readily upon injection of a pressurized liquid.
[0095] Thus, according to one aspect, the presently disclosed
and/or claimed inventive concept(s) provides for the use of a first
and second capsule element in the process according to the
presently disclosed and/or claimed inventive concept(s), wherein
the first capsule element comprises a rim for sealing engagement
with the second capsule element, and further comprises at least one
sidewall, and a bottom wall. The first capsule element can for
example comprise one, at least two, at least three, at least four,
at least five, or at least ten sidewalls. In certain non-limiting
embodiments, it may be desired that the first capsule element
comprises one sidewall such as a frusto-conical sidewall.
[0096] The at least one side wall and the bottom wall define an
interior chamber having an opening. The opening spans a plane. In
certain non-limiting embodiments, the rim of the first capsule
element extends outwards from the sidewall and surrounds the
opening. In certain particular, non-limiting embodiments, the rim
is bent into the direction of the bottom wall, the rim and the
plane forming an angle of at least about 10.degree., such as (but
not limited to) at least about 12.degree.. The angle formed may be
about 10.degree. to about 31.degree., about 10.degree. to about
28.degree., about 12.degree. to about 26.degree., about 14.degree.
to about 24.degree., about 16.degree. to about 22.degree., or about
18.degree. to about 20.degree.. The angle can be 10.degree.,
11.degree., 12.degree., 13.degree., 14.degree., 15.degree.,
16.degree., 17.degree., 18.degree., 19.degree., 20.degree.,
21.degree., 22.degree., 23.degree., 24.degree., 25.degree.,
26.degree., 27.degree., 28.degree., 29.degree., or 30.degree.. In
certain non-limiting embodiments, the angle is about 12.degree. to
about 28.degree., such as about 16.degree. to about 28.degree., or
about 18.degree. to about 26.degree.. Other non-limiting examples
are angles of about 20.degree. to about 28.degree., such as about
22.degree. to about 26.degree., or about 24.degree..
[0097] The rim can be pre-bent, and thus present before a sealing
engagement between the first capsule element and a further capsule
element occurs.
[0098] The rim of the first capsule element can comprise a flat
annular part. The rim of the first capsule element may be a
flange-like rim. The rim of the first capsule element may be a
flange-like rim comprising a flat annular part.
[0099] The angle can be determined prior to the sealing connection
of the first capsule element with the second capsule element, for
example on the first capsule element taken in isolation, in
particular if the rim is a pre-bent rim.
[0100] In certain non-limiting embodiments, the sealing connection
between the first capsule element and the second capsule element,
e.g., membrane, is provided on the flat annular part.
[0101] Without wishing to be bound by theory, the present inventors
have found that surprisingly, the angle between the rim and the
plane of the opening attributes increased pressure resistance to
the hermetically sealed capsule obtained by sealing the first and
second capsule elements in step (d) of the process according to the
presently disclosed and/or claimed inventive concept(s).
[0102] The first capsule element may be a capsule body.
[0103] According to a particular (but non-limiting) embodiment, the
first capsule element is rotationally symmetric and/or is of
essentially frusto-conical shape, or frusto-conical shape. In
certain non-limiting embodiments, the sealing connection of the
second capsule element with the rim extends, from the inner sealing
point to the outer sealing point, along a rectilinear direction,
when the capsule is viewed in cross-sectional view. As result, the
resistance to any delamination (including any initiation of
delamination) of the membrane, is increased.
[0104] In certain non-limiting embodiments, the second capsule
element is a membrane.
[0105] The membrane can have a thickness about 30 .mu.m to about 40
.mu.m. In certain non-limiting embodiments, the membrane is
impermeable for air (CO.sub.2, CO, O.sub.2, N.sub.2, . . . ) and
coffee aroma volatiles, i.e., gas-tight. The membrane can comprise
or consist of any suitable material, such as aluminium or a
multi-layer comprising the following layers (from exterior to
interior): PET/Colour layer/Adhesive/Aluminium/Adhesive/OPP.
[0106] Capsule elements and capsules useful in the process
according to the presently disclosed and/or claimed inventive
concept(s) will be described in even further detail below.
[0107] According to a further aspect, a vacuum or a reduced
pressure can be applied to the first capsule element. Thus, a
partial vacuum or reduced pressure can be created within the
capsule by providing a negative pressure before fully sealing the
capsule. This way, the coffee ingredient, such as coffee, in the
capsule is given the capacity to release carbon gas while
maintaining the pressure inside the capsule sufficiently low.
[0108] A vacuum or a reduced pressure can be applied to the first
capsule element or capsule after filling the ground coffee
ingredient into the first capsule element and before the first
capsule element is entirely hermetically sealed with the second
capsule element. The reduced pressure applied to the first capsule
element can be about 100 mbar to about 800 mbar under atmospheric
pressure, such as about 200 mbar to about 700 mbar, about 300 mbar
to about 600 mbar, or about 400 mbar to about 500 mbar under
atmospheric pressure. In certain non-limiting embodiments, it may
be desired that the reduced pressure applied is about 600 mbar to
about 800 mbar, such as about 650 mbar to about 750 mbar, or about
700 mbar to about 770 mbar under atmospheric pressure. In normal
conditions, the atmospheric pressure can be generally about 1013.25
mbar (+/-100).
[0109] The reduced pressure can be applied prior to step (d) and/or
during sealing step (d). The vacuum or reduced pressure can be
applied after filling step (c) and prior to sealing step (d). The
vacuum or reduced pressure can be applied after filling step (c)
and during sealing step (d). The vacuum or reduced pressure may be
applied at some point during step (d), before the hermetically
sealing is fully completed.
[0110] During application of the vacuum or reduced pressure, the
coffee ingredient can be cooled, and/or can be maintained at a
certain temperature, as desired. For example, the coffee ingredient
can be cooled to or maintained at a temperature of about
-50.degree. C. to about 10.degree. C., about -45.degree. C. to
about 5.degree. C., about -40.degree. C. to about 0.degree. C.,
about -35.degree. C. to about -5.degree. C., about -30.degree. C.
to about -10.degree. C., such as (but not limited to) about
-25.degree. C. to about -15.degree. C., or about -20.degree. C.
Other non-limiting examples include temperatures of about
-5.degree. C. to about 10.degree. C., such as about -3.degree. C.
to about 8.degree. C., about 2.degree. C. to about 7.degree. C., or
about 5.degree. C.
[0111] Particular (but non-limiting) means for applying a vacuum or
a reduced pressure that can be used for applying a vacuum or a
reduced pressure to a capsule element or capsule are described in
co-pending patent application PCT/EP13/063174.
[0112] By applying a vacuum or a reduced pressure, the emission of
gas in the hermetically sealed capsule can be partially or entirely
compensated for. In other words, the increase of pressure in the
capsule due to the emanation of carbon gas from the coffee
ingredient can be substantially equal to the reduction of pressure
applied before sealing step d).
[0113] The skilled person understands that both aspects useful to
compensate for the emission of gas in the capsule can be used in
combination. Hence, the presently disclosed and/or claimed
inventive concept(s) also provides for the application of a vacuum
or reduced pressure when a first capsule element comprising a rim
for sealing engagement with the second capsule element is used, the
capsule element further comprising at least one sidewall, and a
bottom wall, the side wall and the bottom wall defining an interior
chamber having an opening, the opening spanning a plane, the rim of
the first capsule element extending outwards from the sidewall and
surrounds the opening, the rim being bent into the direction of the
bottom wall, the rim and the plane of the opening forming an angle
of at least about 10.degree., such as (but not limited to) of at
least about 12.degree..
[0114] FIG. 1 shows an exemplary, non-limiting example of a process
according to the presently disclosed and/or claimed inventive
concept(s). According to the exemplary process of FIG. 1, a coffee
ingredient that is roasted coffee beans is provided as starting
material. The process starts with step 1, tempering of the coffee
beans. In a second step 2, the tempered coffee beans are cooled
with liquid nitrogen. Optionally, N.sub.2-gas is exhausted 3. This
can be done by using a fan or the like. The cooled beans are
subsequently subjected to grinding step 4, followed by normalizing
or compacting step 6, degassing step 8, and filling step 10. Steps
4, 6, and 8 are carried out while maintaining the coffee ingredient
cold. To that end, cooling units 5, 7 and 9 are used for steps 4, 6
and 8, respectively.
[0115] FIG. 2 shows a further exemplary, non-limiting example of a
process according to the presently disclosed and/or claimed
inventive concept(s). Coffee beans are the coffee ingredient that
is used as starting material. The process optionally starts with a
roasting step. The roasted beans are transferred for tempering
under N.sub.2-flushing, or the beans are cooled to a temperature of
about -20.degree. C. under ambient air, to provide pre-cooled
roasted coffee beans. The pre-cooled coffee beans are then
subjected to grinding, followed by a normalizing/compacting step,
degasification step, and the steps of filling into capsules and
sealing. The grinding step can be performed under ambient air or
under cooled conditions such as under N2-flushing, while the
normalizing/compacting step, the degasification step, and the steps
of filling and sealing are performed under N.sub.2-flushing. A
cooling unit provides a cooling fluid such as a mixture of water
and glycol for a cooling circuit during grinding,
normalizing/compacting, and degasification.
[0116] Capsule elements and capsules according to the presently
disclosed and/or claimed inventive concept(s).
[0117] The presently disclosed and/or claimed inventive concept(s)
also provides for a capsule obtainable by a process according to
the presently disclosed and/or claimed inventive concept(s). The
capsule comprises a ground coffee ingredient, such as (but not
limited to) ground coffee. In certain particular, non-limiting
embodiments, the capsule is adapted for insertion into a beverage
producing unit. The capsule can be a capsule comprising a membrane
as the second capsule element. The capsule can comprise a single
serving of the ground coffee ingredient, such as the ground
coffee.
[0118] A capsule obtainable by a process according to the presently
disclosed and/or claimed inventive concept(s) can be distinguished
from capsules of the prior art in one or more of the following
aspects.
[0119] For example, a capsule obtainable by a process according to
the presently disclosed and/or claimed inventive concept(s) can
comprise a ground coffee ingredient that has a higher content of
one or more VSs, such as VOCs, than a capsule comprising a ground
coffee ingredient obtainable by a process according to the prior
art, when the same coffee ingredient is used as a starting material
and the same amount of ground coffee ingredient is comprised within
the capsule.
[0120] Absolute and/or relative contents in the ground coffee
ingredient, such as ground coffee of one or more VSs, such as VOCs,
can be higher for a capsule obtainable by a process according to
the presently disclosed and/or claimed inventive concept(s). Also,
a capsule obtainable by a process according to the presently
disclosed and/or claimed inventive concept(s) can comprise more of
one or more VSs, such as VOCs, relative to a capsule comprising a
ground coffee ingredient obtainable by a process according to the
prior art, when the same coffee ingredient is used as a starting
material. Non-limiting examples of VSs that can be determined can
be selected from the group consisting of thiols, sulfides, Strecker
aldehydes, diketones, pyrazines, phenols or a combination
thereof.
[0121] The aroma in cup of coffee prepared from a capsule
obtainable by a process according to the presently disclosed and/or
claimed inventive concept(s) was found to be increased by +20% to
+30% (compared to the same capsule without the process of the
presently disclosed and/or claimed inventive concept(s) as
considered as a reference), and the aroma above the cup was found
to be increased by +35% to +70% compared to a capsule prepared
according to the process of the prior art wherein neither cooling
nor reduced or eliminated degasing times were applied.
[0122] In the alternative or in addition, a capsule obtainable by a
process according to the presently disclosed and/or claimed
inventive concept(s) can be characterized by a higher pressure,
and/or a higher content or concentration of carbon gas within the
capsule than a capsule comprising a ground coffee ingredient
obtainable by a process according to the prior art, when the same
coffee ingredient is used as a starting material, and the same
amount of ground coffee ingredient is comprised within the
capsule.
[0123] Likewise in the alternative or in addition, a capsule
according to the presently disclosed and/or claimed inventive
concept(s) can be distinguished from a capsule of the prior art by
the presence of a specific angle between a rim of a first capsule
element having an opening and a plane of the opening. In
particular, the capsule can be a capsule comprising a first capsule
element, the first capsule element comprising a rim for sealing
engagement with a second capsule element, at least one sidewall,
and a bottom wall, wherein the at least one side wall and the
bottom wall define an interior chamber having an opening, the
opening spanning a plane, wherein further the rim extends outwards
from the sidewall and surrounds the opening, the rim being bent
into the direction of the bottom wall, the rim and the plane of the
opening forming an angle of at least about 10.degree., such as (but
not limited to) at least about 12.degree..
[0124] The presently disclosed and/or claimed inventive concept(s)
also provides for a capsule element for a capsule comprising a
ground coffee ingredient, wherein the capsule element comprises a
rim for sealing engagement with a second capsule element, at least
one sidewall, and a bottom wall.
[0125] The capsule element can for example comprise one, at least
two, at least three, at least four, at least five, or at least ten
sidewalls. In certain non-limiting embodiments, it may be desired
that the first capsule element comprises one sidewall, such as (but
not limited to) a frusto-conical sidewall.
[0126] The at least one side wall and the bottom wall define an
interior chamber having an opening. The rim extends outwards from
the sidewall and surrounds the opening. The opening spans a plane.
In certain non-limiting embodiments, the rim is bent into the
direction of the bottom wall. This means that the angle formed by
the rim and the sidewall(s) is acute or lower than 90.degree..
[0127] The rim and the plane of the opening form an angle of at
least about 10.degree., such as (but not limited to) at least about
12.degree.. The angle formed may be about 10.degree. to about
31.degree., about 10.degree. to about 28.degree., about 12.degree.
to about 26.degree., about 14.degree. to about 24.degree., about
16.degree. to about 22.degree., or about 18.degree. to about
20.degree.. The angle can be 10.degree., 11.degree., 12.degree.,
13.degree., 14.degree., 15.degree., 16.degree., 17.degree.,
18.degree., 19.degree., 20.degree., 21.degree., 22.degree.,
23.degree., 24.degree., 25.degree., 26.degree., 27.degree.,
28.degree., 29.degree., or 30.degree.. In certain non-limiting
embodiments, the angle is about 12.degree. to about 28.degree.,
such as about 16.degree. to about 28.degree., or about 18.degree.
to about 26.degree.. Other non-limiting examples are angles of
about 20.degree. to about 28.degree., such as about 22.degree. to
about 26.degree., or about 24.degree..
[0128] The rim can be pre-bent, and thus be present before a
sealing engagement between the capsule element and a further
capsule element occurs.
[0129] The angle can be determined prior to the sealing connection
of the capsule element with the second capsule element, for example
on the capsule element taken in isolation, in particular if the rim
is a pre-bent rim.
[0130] The rim of the capsule element can comprise a flat part,
such as (but not limited to) annular. The rim of the capsule
element can be a flange-like rim. The rim of the capsule element
can be a flange-like rim comprising a flat annular part and a
curled flange.
[0131] The angle between the rim and the plane of the opening can
be determined by the level between two points placed on a flat part
of the rim.
[0132] The angle between the plane of the opening and the rim can
be the angle between the plane of the opening and a straight line
passing through two points on the rim, such as (but not limited to)
on a flat part of the rim, wherein the two points are points of
intersection of a second plane and the rim, the second plane being
a plane passing through the centre of the opening and being
orthogonal to the plane of the opening.
[0133] The flat part of the rim constitutes all or part of the
sealing connection for the second capsule element with the first
capsule element. As a result, the resistance to delamination is
obtained solely by the inclination of the rim at the flat part and
is not obtained by other means, such as a preformed recess in the
lower face of the rim for providing a wedge effect, and/or a
partial delamination providing a reserve for an excess of gas.
[0134] Capsules comprising a capsule element according to the
presently disclosed and/or claimed inventive concept(s) can
withstand a higher internal capsule pressure. This is particularly
true for embodiments where the second capsule element is a
membrane, especially where the membrane is comparably thin, as the
case may be for capsules adapted for insertion into and/or use with
a beverage production device. The present inventors have found that
upon increased internal capsule pressure, the membrane deforms
outwardly to form, ultimately followed by bursting and/or
delamination of the membrane from the first capsule element.
However, if a capsule element having a rim as described above is
used as the first capsule element, the membrane periphery aligns in
the direction of the inclined rim when forming a dome. The
orthogonal force component is so lower making the strength against
delamination of the membrane on the rim much higher.
[0135] The rim of the capsule element may be a flange-like rim.
[0136] The sidewall of the capsule element can have an upper and a
lower end, the upper end defining a circle having a first diameter,
the lower end defining a circle having a second diameter, wherein
the opening is located at the upper end. The second diameter can be
smaller than the first diameter. The bottom wall can be located at
the lower end. The bottom wall can be located opposite the
opening.
[0137] The capsule element can be a capsule body. In the
alternative or in addition, the capsule element can be rotationally
symmetric or a combination thereof. In certain non-limiting
embodiments, the capsule element is of essentially frusto-conical
shape or of frusto-conical shape.
[0138] The capsule element is formed of a substantially gas-tight,
gas tight material. The capsule element can comprise or can be made
of any suitable material such as, but not limited to, aluminium or
a polymer composition. The polymer composition can be polypropylene
or polyethylene but may comprise (in certain non-limiting
embodiments) a gas barrier layer such as EVOH. Aluminium is a
desired (but non-limiting) material. A laminate of polymer and
aluminium is possible such as aluminium-PP.
[0139] The capsule element can further comprise a sealing means.
The sealing means can be applied to or connected with the rim of
the capsule element, so as to allow sealing engagement with a
further capsule element, which may be different from the first
capsule element. The sealing means can be a sealing lacquer and the
like.
[0140] In certain non-limiting embodiments, it may be desired that
the capsule element according to the presently disclosed and/or
claimed inventive concept(s) is a capsule element for preparing a
beverage, such as coffee. In certain particular non-limiting
embodiments, it may further be desired that the capsule element is
adapted for insertion into and/or use with a beverage production
device.
[0141] A schematic drawing of one embodiment of an exemplary
capsule according to the presently disclosed and/or claimed
inventive concept(s) is shown in FIG. 3. The capsule shown in FIG.
3 is a particular (but non-limiting) embodiment; however, the
skilled person understands that the presently disclosed and/or
claimed inventive concept(s) is not limited thereto.
[0142] The presently disclosed and/or claimed inventive concept(s)
further provides for a capsule comprising as a first capsule
element a capsule element according to the presently disclosed
and/or claimed inventive concept(s), the capsule further comprising
a second capsule element for sealing connection with the rim of the
first capsule element. The sealing means can be a sealing lacquer
and the like.
[0143] The second capsule element may be in a sealing connection or
a hermetically sealing connection with the rim of the first capsule
element. Optionally, the sealing or hermetically sealing connection
may be mediated by a sealing means located between the rim of the
first capsule element and the adjacent part of the second capsule
element. The hermetically sealing connection is substantially
gas-tight, or is gas tight.
[0144] According to a particular, non-limiting embodiment, the
second capsule element is a membrane. The membrane may have a
thickness of about 30 .mu.m to about 40 .mu.m, such as about 33
.mu.m to about 37 .mu.m, or about 35 .mu.m. The membrane may be
embossed in which case the thickness is regarded as the thickness
of the membrane as it was non-embossed and free of lacquer. In the
alternative or in addition, the membrane may be impermeable, or
substantially impermeable for CO.sub.2. In certain non-limiting
embodiments, the membrane is substantially gas-tight, or is gas
tight. The membrane can comprise or consist of any suitable
material, such as aluminium.
[0145] In certain non-limiting embodiments, the capsule may
comprise a coffee ingredient such as (but not limited to) roast and
ground coffee.
[0146] The pressure within the capsule may be about 300 mbar to
about 500 mbar, about 325 mbar to about 475 mbar, about 350 mbar to
about 450 mbar, about 375 mbar to about 425 mbar or about 400
mbar.
[0147] The pressure within the capsule can be determined manually
by putting the capsule into a pressure controlled box. The pressure
is varied until the absolute internal pressure of the capsule
(mbar) is equivalent to the absolute pressure in the box (mbar);
when the membrane of the capsule becomes floppy at this point. The
internal pressure is considered as equal to the absolute pressure
in the box and the relative pressure of the capsule is given by the
absolute pressure according to the atmospheric pressure. The
pressure within the capsule can be a pressure determined after 7
days of storage under ambient (20.degree. C.) conditions.
[0148] In certain non-limiting embodiments, it may be desired that
the capsule according to the presently disclosed and/or claimed
inventive concept(s) is a capsule for preparing a beverage, such as
coffee. In particular non-limiting embodiments, it may further be
desired that the capsule is adapted for insertion into and/or use
with a beverage production device. Accordingly, the capsule may be
adapted to allow for the opening of the capsule upon injection of a
pressurized liquid, e.g. by tearing or disruption of a capsule
element, such as a membrane.
[0149] In further particular non-limiting embodiments, it may be
desired that capsule is a capsule comprising a single serving of
ground coffee (e.g., from 5 g-12 g of ground coffee). In yet
further particular, non-limiting embodiments, this capsule is an
hermetically or gas-tightly sealed capsule.
[0150] The capsule can be stored at a wide range of temperatures,
such as from about -30.degree. C. to about 50.degree. C., such as
from about -20.degree. C. to about 40.degree. C., or from about
-10.degree. C. to about 30.degree. C., or about 0.degree. C. to
about 20.degree. C.
[0151] A schematic drawing of one embodiment of an exemplary
capsule according to the presently disclosed and/or claimed
inventive concept(s) is shown in FIG. 3. The capsule shown in FIG.
3 is a particular (but non-limiting embodiment); however, the
skilled person understands that the presently disclosed and/or
claimed inventive concept(s) is not limited thereto.
[0152] FIG. 3A shows a schematic side-view of the capsule. The
capsule comprises a first capsule element 21 that is of essentially
frusto-conical shape and has a side-wall 22 and a bottom wall 23,
the side wall and the bottom wall defining an interior chamber 24
having an opening 25. Element 21 comprises a flange-like rim 26
comprising a flat part 27 and a flange 28 that is curled in certain
non-limiting embodiments. The capsule further comprises a second
capsule element 30 that is a membrane. It is apparent that the
membrane is sealed on a portion (at least) of the flat part 27,
without any recess being formed in the rim in this sealed region.
Therefore, the start of the delamination is not promoted.
[0153] The flat part of the rim 26 and a plane P spanned by the
opening 25 form an angle A of about 12.degree., as can be seen in
more detail in FIG. 3C.
[0154] FIG. 3B shows additional views of capsule element 21.
EXAMPLES
[0155] The following examples are not to be construed as
limiting.
Example 1
[0156] A capsule comprising ground coffee was prepared, as
schematically depicted in FIG. 1.
[0157] Initially, coffee beans were roasted, followed by storing in
the existing tempering silo or storage at -20.degree. C. Then,
beans were fed into the cryogenic equipment. Liquid nitrogen was
injected inside the cryogenic equipment, where the beans are in
direct contact with the liquid nitrogen. In direct contact with the
beans, the liquid nitrogen cools down the beans to the setup
temperature value. The beans temperature at the exit of the
cryogenic equipment can be adjusted by the ratio between the amount
of beans and of liquid nitrogen inside the cryogenic equipment and
by the residence time of the beans inside the cryogenic
equipment.
[0158] A fan can optionally be used to exhaust to the outside the
N.sub.2-gas expanded from the liquid nitrogen evaporation (or to
recirculate gas to the grinder for example). The cold beans were
fed into the grinder. The grinder rolls were cooled by circulation
of a cooling fluid (additionally or alternatively, liquid nitrogen
could be injected inside the grinder to contact the coffee
ingredient). Then, the roasted and ground coffee was compacted by
adjustment of the normalizer head opening. The normalizer double
jacket was cooled by circulation of a cooling fluid. The coffee is
degassed in the degasing unit. This can be done by adjusting the
coffee load. The degasing unit double jacket was likewise cooled by
circulation of a cooling fluid. Finally, the roasted and ground
coffee was dosed in capsules in the filling line. In a possible
alternative, the coffee ingredient could be cooled inside the
filling line and dosing unit with indirect cooling such as by using
a double-jacket circuit, or with direct injection of liquid
nitrogen. Also due to operational constraints and to avoid coffee
aroma loss during the temporary line stoppage, additional equipment
may be required to maintain the coffee cold during such
interruptions.
Example 2
[0159] The aroma of capsules comprising ground coffee prepared
according to a process of the presently disclosed and/or claimed
inventive concept(s) was evaluated. The process is the one
described in Example 1.
[0160] To that end, the in-cup aroma and the in-room aroma of the
capsules was analyzed as outlined below.
[0161] Experimental Setup
[0162] a) In-Cup Coffee Odorant Analysis:
[0163] Absolute contents (ppm/g roasted and ground coffee) of key
coffee odorants (thiols, sulfides, Strecker aldehydes, diketones,
pyrazines and phenols) were determined in-cup using the
corresponding isotopic labelled standards in conjunction with
SPME/GC/MS (Solid Phase Micro Extraction fiber with Gas
Chromatography combined with Mass Spectrometer detector). The
coffee odorants were extracted from the roast and ground by
weighing 4 g roast and ground (taken from different freshly opened
capsules) in 100 mL boiling water and leaving the suspension to
extract for 15 min under continuous stirring using a magnetic
stirring bar. Every sample was extracted and measured in
triplicate. The analysis was split into two groups of analytes.
[0164] Group 1 (Analysis of Thiols, Sulfides and Pyrazines)
[0165] After extraction, the coffee samples were quickly cooled on
ice and 100 mg of cysteine was added to the coffee samples to avoid
thiol binding to the coffee matrix during sample work up. Definite
amounts of isotope labeled standards were added and the solutions
were stirred for 10 min. Subsequently, portions of 7 mL were
transferred to headspace vials.
[0166] After an equilibration (40.degree. C., 1 min), the aroma
compounds were extracted from the headspace during 10 min at
40.degree. C. under agitation (350 rpm) using a
divinylbenzene-carboxen-polydimethylsiloxane SPME fiber (StableFlex
DVB/CAR/PDMS; 2 cm; film thickness 50/30 .mu.m; Supelco, Buchs,
Switzerland). The extracted compounds were thermally desorbed for 3
min into a split/splitless injector maintained at 240.degree. C.
and operated in splitless mode. For separation of compounds, an
Agilent 7890A gas chromatograph (Agilent Technologies, Morges,
Switzerland) with a 60 m.times.0.25 mm.times.0.25 .mu.m DB-Wax
column was used (Agilent Technologies, Morges, Switzerland). Helium
was used as a carrier gas with a constant flow of 1.3 mL/min, and
the following temperature program was applied: 40.degree. C. (6
min), 4.degree. C./min, 140.degree. C. (0 min), 20.degree. C./min,
240.degree. C. (10 min). The gas chromatograph was coupled to a
5975C mass spectrometer (Agilent Technologies, Morges, Switzerland)
operating in single ion monitoring (SIM) mode using electron
ionization and an ionization potential of 70 eV. All GC-MS
measurements were run in triplicate. Data were analysed using the
MassHunter Quant software (Version B.05.02, Agilent
Technologies).
[0167] Group 2 (Strecker Aldehydes, Diketones and Phenols)
[0168] After cooling the coffee samples on ice and diluting until a
final volume of 100 mL, a 4:1 additional dilution was performed.
Definite amounts of isotope labeled standards were added and the
solutions were stirred for 10 min. Portions of 7 mL were
transferred to headspace vials.
[0169] The coffee volatiles were extracted and injected into a
Thermo Trace Ultra gas chromatograph (Brechbuhler, Schlieren,
Switzerland) as described above for Group 1. In contrast to Group
1, volatiles were separated on a 60 m.times.0.25 mm.times.1.4 .mu.m
DB-624 column (Agilent Technologies, Morges, Switzerland). Helium
was used as a carrier gas with a constant flow of 1.3 mL/min, and
the following temperature program was applied: 40.degree. C. (6
min), 6.degree. C./min, 140.degree. C. (0 min), 20.degree. C./min,
240.degree. C. (10 min). The gas chromatograph was coupled to a
Thermo Scientific ISQ mass spectrometer (Brechbuhler, Schlieren,
Switzerland) operating in single ion monitoring (SIM) mode using
electron ionization and an ionization potential of 70 eV. All GC-MS
measurements were run in triplicate. Data were analysed using the
Xcalibur 2.1 software (Thermo Scientific).
[0170] Samples which were produced according to a process of the
presently disclosed and/or claimed inventive concept(s) were
compared to the corresponding reference sample.
[0171] b) Around Machine Coffee Odorant Analysis (Method Using
Tenax-GC-MS):
[0172] The amount of aroma released around a coffee machine (in
microgram) was measured in a hermetically closed glovebox, having
electricity supply and containing the coffee machine. Coffees were
prepared inside the glovebox using the capsule/machine
configuration, using a Nespresso "U" (trademark) machine. A similar
preparation was done for reference and samples treated with
cryogenic equipment. A representative air sample (225 ml) was
sampled from this glovebox directly after beverage preparation. The
coffee aroma was trapped onto a Tenax trap (Markes International,
Llantrisant, UK), involving a tube packed with Tenax TA adsorbent
resin to trap the volatiles passing through the tube. The Tenax
trap was subsequently desorbed to the GC-MS in splitless mode by a
TD-100 autosampler (Markes International, Llantrisant, UK). The
compounds were separated on a DB-FFAP GC column (60 m.times.0.250
mm.times.25 um) using following temperature gradient: 30.degree. C.
for 10 min; increase at 4.degree. C./min until 50.degree. C.;
increase at 10.degree. C./min until 245.degree. C. and hold until
35 min. The components were detected by a 5975C single quad mass
spectrometer (Agilent Technologies, Morges, Switzerland) operating
in SIM mode. Data were analysed using the MassHunter Quant software
(Version B.05.02, Agilent Technologies). Again, a representative
group of key coffee odorants (thiols, sulfides, Strecker aldehydes,
diketones, pyrazines and phenols) was measured. Samples which were
produced according to a process of the presently disclosed and/or
claimed inventive concept(s) were compared to the corresponding
reference sample. Every sample was extracted and measured at least
four times.
[0173] Results
[0174] The table below gives an overview of the differences
measured in-cup and around the machine in terms of the key coffee
odorants. For every blend, a comparison was made with the
corresponding reference product, which was considered as 100%.
TABLE-US-00001 comparison (%) relatively to untreated product
(considered as 100%) in-cup error (%) around machine error (%)
Arpeggio 130 2 169 11 Ristretto 134 5 135 16 Indryia 121 6 n/a Roma
124 5 n/a Fortissio 123 9 n/a Other blend 130 2 n/a
Example 3
[0175] In a further experiment, the capsules were evaluated by
determining sensory profiles.
[0176] Experimental Setup
[0177] Comparative profiles were obtained from 12 assessors using a
simplified cupping procedure determining crema, aroma, flavour, and
texture. The procedure was repeated once. Nespresso Concept
(trademark) machines filled with Nestle Aqua Panna water were used
to test the capsules according to the presently disclosed and/or
claimed inventive concept(s) as well as reference capsules at 40 ml
of dosage.
[0178] Sensory Profiles
[0179] The objective was to evaluate the sensory impact of the
coffee prepared from capsules obtained according to a process of
the presently disclosed and/or claimed inventive concept(s). The
coffee beans were roasted coffee, tempered and pre-cooled at
-20.degree. C. and then ground, normalized and degased during 5 min
at 5.degree. C. The roast and ground coffee was then directly
filled into the capsule at the corresponding weight depending of
the blend. The capsules were evaluated against capsules containing
coffee processed according to a standard process (reference). In
the standard process, coffee beans were roasted, tempered, ground,
normalized, then degased during 30 min at 30.degree. C. and then
directly filled into the capsule at the corresponding weight
depending of the blend. A lot of attributes were found to be
significantly improved in the intense coffee blends prepared
according to the presently disclosed and/or claimed inventive
concept(s):
[0180] Arpeggio (a coffee blend identical to the one contained in
the commercial Arpeggio capsule) from a capsule produced according
to the presently disclosed and/or claimed inventive concept(s)
(batch 222173) was perceived more intense and roasty in flavour,
more bitter/persistent than the reference (batch 216205) as well as
with more body. The crema was found darker and with more quantity.
See also FIG. 4. Bars with spaced hatching signify the presence of
a significant difference for a given attribute, confidence interval
95%.
[0181] Roma (a coffee blend identical to the one contained in the
commercial Roma capsule) from a capsule produced according to the
presently disclosed and/or claimed inventive concept(s) (batch
228195) was found more intense/roasty/cereal in overall aroma and
flavour as well as more persistent than the reference (batch
228193). See also FIG. 5. Bars with spaced hatching signify the
presence of a significant difference for a given attribute,
confidence interval 95%.
[0182] Ristretto (a coffee blend identical to the one contained in
the commercial Ristretto capsule) from a capsule produced according
to the presently disclosed and/or claimed inventive concept(s)
(batch 227025) was darker, more intense in overall aroma/flavour,
more roasty (aroma/flavour), less fruity (flavour), more robusta,
more bitter, less smooth with more body and more persistent that
the reference (batch 222569). See also FIG. 6. Bars with spaced
hatching signify the presence of a significant difference for a
given attribute, confidence interval 95%.
Example 4
[0183] It was demonstrated that the aroma retention increases with
a decrease of the processing temperature. Cold processing with
pre-cooled roasted coffee enhances aroma recovery. Consumer
preference was also demonstrated by preference test: win on
Arpeggio with similar net weight and parity on Fortissio with
reduced net weight.
[0184] However, due to the reduced degassing time and temperature
during cold processing, higher retention of CO.sub.2 results in a
higher internal pressure in the filled and sealed capsule. Together
with the aroma retention, the carbon dioxide release from the
coffee is reduced, which leads to higher capsule internal pressure.
Consequently, this higher internal capsule pressure was raised as a
major technical constraint when using cold processing with
pre-cooled roasted coffee.
[0185] Preliminary results from mechanistic model have demonstrated
that increased initial rim angle should help the membrane to resist
to higher pressures. Consequently, the objective was to demonstrate
the impact of higher rim angle at laboratory scale on capsule
resistance in order to see potential benefit for capsules with
over-pressure as well as the impact of thicker membrane.
[0186] The objective was to modulate the capsule internal pressure
from 300 mbar to 500 mbar with higher rim angle (12 to 28 degrees).
Trials with the standard membrane (30 .mu.m) were performed on
Arpeggio blend under different degassing and temperature conditions
with cold processing, as shown in FIG. 2.
[0187] From 12.degree. to 16.degree. rim angles, capsules were bent
directly on the pilot plant. Other capsules with rim angles
superior to 16.degree. at time zero were bent manually.
[0188] Process parameters are summarized in the table below.
TABLE-US-00002 Cooling water T.degree. C. Roasted Grinder/ Beans
Normalizer/ Membrane Internal temp. Degassing Degassing Thickness
Rim Angle Pressure Trials (.degree. C. ) unit time (min) (.mu.m)
(degree) (mbar after 7 days) Arpeggio Ref. -20
5.degree./5.degree./30.degree. C. 5/20/35 30
12.degree./16.degree./19.degree. 300/400/500 1
21.degree./28.degree. Ref. -20 5.degree./5.degree./5.degree. C.
5/20/35 12.degree./16.degree./19.degree. 300/400/500 2
21.degree./28.degree. Ristretto Ref. 3 Industrial trial conditions
40 12.degree. 400/500
[0189] Capsules were analyzed for internal pressure. Capsule
internal pressure was measured by placing the capsule in a
pressurized chamber (as described earlier) 7 days after
filling.
[0190] Rim angles were measured at time zero and 3 times over 8
weeks with a laser instrument. The instrument is a laser which can
measure the angle between the two points as described in the
present patent application.
[0191] The rim angle was defined by the level between two points
placed on the flat part of the rim. These two points have to be on
the capsule diameter. Membrane protection just after the sealing
process and delamination are the two arguments which play a role
for the rim angle determination. Based on these two arguments, it
was demonstrated that the recommended folding angle was around
12.+-.2.degree. in order to avoid the membrane damage and limit
delamination (for capsules showing high internal pressure).
[0192] Capsule resistance was tested visually on the membrane.
[0193] Delamination Test: Storage test consists of the delamination
evaluation (visual capsule resistance) of the Arpeggio or Ristretto
capsules produced under different conditions of cold processing
(rim angles & capsule internal pressure; see trials description
above). All capsules are kept in temperature and humidity
controlled chambers at 30.degree. C. and 70% Rh (relative
humidity). The capsules resistance was evaluated every week over 3
months which mimic one year shelf life at room temperatures.
[0194] Capsule resistance was found to increase with higher rim
angle. At 500 mbars of capsule internal pressure, no delamination
was observed over the 3 months at 30.degree. C. with rim angle
>20.degree.. Capsule resistance at intermediate internal
pressure (400 mbar) was visually ok from rim angles >16.degree..
Delamination of the membrane was only observed from 12.degree. to
16.degree. on one capsule after 6 weeks at 30.degree. C. with
standard membrane (30 .mu.m) and no delamination noted with the
thicker membrane (40 .mu.m). Rim angles noted correspond to
measurements performed at time zero.
[0195] Exemplary results for 30 .mu.m and 40 .mu.m membranes are
shown in FIGS. 7 and 8, respectively. FIG. 7 shows capsule
resistance over 3 months at 30.degree. C./70% Rh (internal pressure
from 300 to 500 mbars and rim angles from 12.degree. to 28.degree.
with a standard membrane 30 .mu.m). FIG. 8 shows capsule resistance
over 3 months at 30.degree. C./70% Rh (internal pressure from 400
to 500 mbars and rim angles from 7.degree. to 28.degree. with a
thicker membrane 40 .mu.m)
[0196] To summarize, capsule over-pressure (up to 500 mbar) can be
managed with higher rim angle.
[0197] Element of a Capsule and Capsule Containing Ground Coffee
Ingredient
[0198] The present invention generally relates to processes for the
preparation of coffee ingredients and to capsules comprising these
coffee ingredients. The invention also relates to capsule elements
and capsules containing coffee ingredients. In particular, the
invention relates to a sealed capsule particularly designed to
resist to delamination and/or breakage, thereby allowing coffee gas
to emanate in the sealed capsule and generating a positive pressure
without risk of damage of the capsule.
[0199] WO2010116284A2 relates to a brewing device and capsule for
preparing a drink such as coffee. The capsule comprises a hollow
element, an extraction membrane and an annular flange. The flange
comprises a recess in the form of annular groove positioned on the
side of the lower face of the flange; such recess communicating
with the interior of the capsule. One objective is to minimize the
risk of accidental delamination between the membrane and the flange
when the capsule is stored. In fact, the membrane is initially
glued to the full surface of the flange but when the force or
pressure exerted on the membrane is too high, such as during coffee
degasing, a wedge effect is produced between the first portion of
the flange and the membrane which allows the membrane to be
retained on the first portion. If the force or pressure reaches a
certain threshold, the membrane is unglued at the recess which
causes the total internal volume of the capsule to increase and the
pressure in the capsule to reduce. However, still delamination of
the membrane can occur. If the reserve of gas provided by the
recess is insufficient, the delamination will continue and cause
leakage. Furthermore, it is very difficult to control the volume of
the recess needed as a function of the coffee pressure release as
such release can depend from many different factors such as coffee
weight, roasting degree, coffee origin, etc. In addition, the
capsule is made relatively more complex.
[0200] The present invention alleviates the drawbacks of the prior
art, as well as, provides new advantages and benefits.
[0201] More generally, during the processing and storage of coffee
ingredients a partial loss of volatile substances (VSs), such as
volatile organic compounds (VOCs), occurs. A reduction in the
content of VSs is undesirable, since it results in a reduced
quality of the obtained product. The reduction of VSs has been
partially attributed to the influence of heat in the processing of
the coffee ingredients.
[0202] For example, coffee is typically processed by first roasting
the coffee beans. The roasted coffee then is allowed to rest so as
to slowly cool down, and afterwards is subjected to grinding. 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. 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.
Grinding the roasted coffee beans will accelerate this process.
[0203] A significant loss of VSs can occur during the further
processing steps and in particular during grinding.
[0204] Therefore, it has been suggested to keep the coffee cool
during further processing steps. Likewise, it has been suggested to
store the obtained product in the cold.
[0205] However, despite these efforts, loss of VSs occurs,
resulting in a reduced aroma of the obtained product and often also
in further deterioration during storage.
[0206] It is therefore desirable to provide improved processes for
the preparation of coffee ingredients, in particular of ground
coffee, which allow the reduction of the loss of VSs from the
ingredient. It is also desirable to provide improved means for use
in relation with these processes and for improved processed
ingredients.
[0207] Accordingly, the present invention provides a process of
preparing a capsule comprising a ground coffee ingredient, the
process comprising the steps of: (a) cooling a coffee ingredient,
in particular coffee beans, to a temperature of about -50.degree.
C. to about 10.degree. C.; (b) grinding the coffee ingredient, in
particular coffee beans, optionally wherein the coffee ingredient
is cooled during grinding; (c) filling the ground coffee ingredient
into a first capsule element, optionally wherein the coffee
ingredient is cooled during filling; and (d) hermetically sealing
the first capsule element with a second capsule element, optionally
wherein the coffee ingredient is cooled during sealing.
[0208] The process can comprise the preliminary step of: (a)'
roasting the coffee ingredient, in particular, coffee beans. Step
(a)' can be performed prior to step (a).
[0209] The process can comprise the step of: (a)'' tempering the
coffee ingredient, in particular, the roasted coffee beans. Step
(a)'' can be performed prior to step (a). Step (a)'' can be
performed after step (a)' and prior to step (a).
[0210] The process can comprise the step of: (c)' compressing the
coffee ingredient, optionally wherein the coffee ingredient is
cooled during compressing. Step (c)' can be performed after step
(b) and prior to step (c).
[0211] The process can comprise the step of: (c)'' degasification
of the coffee ingredient, optionally wherein the coffee ingredient
is cooled during degasification. Step (c)'' can be performed after
step (b) and prior to step (c). Step (c)'' can be performed after
step (c)' and prior to step (c). Preferably, degasification is kept
short to enable a partial loss of the gas contained in the coffee
ingredient.
[0212] Degasification in step (c)'' can be performed for about 120
min or less, for about 60 min or less, for about 35 min or less,
for about 25 min or less, for about 20 min or less, for about 15
min or less, for about 10 min or less, or for about 5 min or
less.
[0213] According to some embodiments, the process does not comprise
a degasification step (c)'', or does not comprise any
degasification step.
[0214] In step (a), the coffee ingredient can be cooled to a
temperature of about -50.degree. C. to about 5.degree. C., about
-45.degree. C. to about 5.degree. C., about -40.degree. C. to about
0.degree. C., about -35.degree. C. to about -5.degree. C., about
-30.degree. C. to about -10.degree. C., about -25.degree. C. to
about -15.degree. C., or about -20.degree. C.
[0215] The coffee ingredient can be maintained at a temperature of
about -50.degree. C. to about 10.degree. C. in step (b). The coffee
ingredient can be maintained at a temperature of about -50.degree.
C. to about 10.degree. C. in step (c). The coffee ingredient can be
maintained at a temperature of about -50.degree. C. to about
10.degree. C. in step (c)'. The coffee ingredient can be maintained
at a temperature of about -50.degree. C. to about 10.degree. C. in
step (c)''. The coffee ingredient can be maintained at a
temperature of about -50.degree. C. to about 10.degree. C. in step
(d).
[0216] The coffee ingredient can be maintained at a temperature of
about -50.degree. C. to about 10.degree. C. in step (b) and/or in
step (c) and/or in step (c)' and/or in step (c)'' and/or in step
(d). The coffee ingredient can be maintained at a temperature of
about -45.degree. C. to about 5.degree. C., about -40.degree. C. to
about 0.degree. C., about -35.degree. C. to about -5.degree. C.,
about -30.degree. C. to about -10.degree. C., about -25.degree. C.
to about -15.degree. C., or about -20.degree. C. in one or more,
preferably all, of these steps. The temperature can be selected
independently for each step.
[0217] The first capsule element can comprise a rim for sealing
engagement with the second capsule element, at least one sidewall,
and a bottom wall, wherein the at least one side wall and the
bottom wall define an interior chamber having an opening, the
opening spanning a plane, wherein further the rim extends outwards
from the sidewall and surrounds the opening, the rim being bent
into the direction of the bottom wall, the rim and the plane of the
opening forming an angle of at least about 10, preferably at least
about 12.degree..
[0218] The angle can be about 10.degree. to about 31.degree., such
as about 12.degree. to about 28.degree., about 12.degree. to about
26.degree., about 14.degree. to about 24.degree., about 16.degree.
to about 22.degree., or about 18.degree. to about 20.degree.. The
angle can be 10.degree., 11.degree., 12.degree., 13.degree.,
14.degree., 15.degree., 16.degree., 17.degree., 18.degree.,
19.degree., 20.degree., 21.degree., 22.degree., 23.degree.,
24.degree., 25.degree., 26.degree., 27.degree., 28.degree.,
29.degree., or 30.degree.. Preferably, the angle is about
12.degree. to about 28.degree., such as about 16.degree. to about
28.degree., or about 18.degree. to about 26.degree.. Even more
preferred are angles of about 20.degree. to about 28.degree., such
as about 22.degree. to about 26.degree., or about 24.degree..
[0219] As will be explained later on, the angle provides a higher
resistance of the second element sealed onto the first element to
delamination and/or breakage and so allows the gas to emanate in
the sealed capsule and generate a positive pressure without risk of
damage of the capsule.
[0220] A vacuum or a reduced pressure can be applied to the first
capsule element after filling the ground coffee ingredient into the
first capsule element and before the first capsule element is
hermetically sealed with the second capsule element.
[0221] The reduced pressure applied to the first capsule element
can be about 100 mbar to about 800 mbar under atmospheric
pressure.
[0222] The first capsule element can be a capsule body. The first
capsule element can be rotationally symmetric. The first capsule
element can be of essentially frusto-conical shape or of
frusto-conical shape.
[0223] The second capsule element can be a membrane. The membrane
can have a thickness of about 30 .mu.m to about 40 .mu.m. The
membrane can be impermeable for CO.sub.2. Preferably, the membrane
is gas-tight.
[0224] Most preferably, the coffee ingredient is roasted
coffee.
[0225] The present invention also provides a capsule obtainable by
the process according to the invention.
[0226] The invention further provides a capsule element for a
capsule comprising a ground coffee ingredient, wherein the capsule
element comprises a rim for sealing engagement with a second
capsule element, at least one sidewall, and a bottom wall, wherein
the at least one side wall and the bottom wall define an interior
chamber having an opening, the opening spanning a plane, wherein
further the rim extends outwards from the sidewall and surrounds
the opening, the rim being bent into the direction of the bottom
wall, the rim and the plane of the opening forming an angle of at
least about 10.degree., preferably at least about 12.degree..
[0227] The angle can be about 10.degree. to about 31.degree., such
as about 10.degree. to about 28.degree., such as about 12.degree.
to about 26.degree., about 14.degree. to about 24.degree., about
16.degree. to about 22.degree., or about 18.degree. to about
20.degree..
[0228] The sidewall can have an upper and a lower end, the upper
end defining a circle having a first diameter, the lower end
defining a circle having a second diameter, wherein the opening is
located at upper end, optionally wherein the second diameter is
smaller than the first diameter. The bottom wall can be located at
the lower end. The bottom wall can be located opposite the
opening.
[0229] The first capsule element can be a capsule body. The first
capsule element can be rotationally symmetric. The first capsule
element can be of essentially frusto-conical shape or of
frusto-conical shape.
[0230] Also, the present invention provides for a capsule
comprising as a first capsule element a capsule element as
described above, the capsule further comprising a second capsule
element for sealing connection with the rim of the first capsule
element.
[0231] The second capsule element can be in sealing connection with
the rim.
[0232] The second capsule element can be a membrane. The membrane
can have a thickness of about 30 .mu.m to about 40 .mu.m. The
membrane can be impermeable for carbon gas (CO2, CO) and aroma
volatiles. Preferably, the membrane is gas-tight.
[0233] The capsule can comprise a coffee ingredient, preferably
roast and ground coffee.
[0234] FIG. 1 shows a non-limiting block diagram depicting
essential and optional steps of a process according to the present
invention.
[0235] FIG. 2 shows a non-limiting block diagram depicting
essential and optional steps of a process according to the present
invention.
[0236] FIG. 3 shows non-limiting schematic drawings of a capsule
according to the invention.
[0237] FIGS. 4 to 6 show results of determining sensory profiles of
capsules.
[0238] FIGS. 7 to 8 show results of experiments analyzing the
impact of the capsule rim angle.
DETAILED DESCRIPTION
[0239] The invention and its advantages are now described in more
detail. It is understood that the examples and drawings provided
herein serve to illustrate aspects of the invention, however are
not to be construed as limiting to the scope of the invention.
Likewise, headlines used in this section are provided for the
convenience of the reader, however are not to be construed as
limiting.
[0240] The expression "about", as used herein, is intended to
signify a range of .+-.10% or less, preferably of .+-.5% or less,
of a given value.
Processes According to the Invention
[0241] The present invention proposes to improve the aromatic
features of the coffee in the capsule so that a higher in-cup
and/or above-cup aroma intensity of the coffee extract can
obtained. Accordingly, the invention proposes to reduce the loss of
aroma volatiles during the processing of coffee ingredients, such
as coffee, by cooling the coffee ingredient, and by preferably
ensuring the maintenance of a cold environment during further
processing steps such as grinding, optional compacting and optional
(reduced) degasification, and eventually filling and capsule
sealing preferably under vacuum.
[0242] The processes according to the present invention allow
reducing the loss of VSs, such as VOCs, and also allow to reduce
oxidation processes occurring during processing and subsequent
storage of the processed coffee ingredient. This is reflected in an
improved aroma of the obtained product.
[0243] The present inventors have found that surprisingly, loss of
VSs, such as VOCs, in the processing of coffee ingredients (in
particular of coffee), can be significantly reduced when at least a
part of the processing is performed under cold conditions, applying
the specific process parameters described herein.
[0244] Accordingly, the aroma quality of coffee was found to be
significantly increased when processed according to a process of
the invention, especially when the aroma above the cup and in the
cup was compared to products of the prior art.
[0245] Moreover, the quality of the obtained ground coffee product
was found to be considerably improved when the product was filled
after reduced degasification into a dedicated capsule and the
capsule subsequently was hermetically sealed.
[0246] Accordingly, in one aspect the present invention provides a
process of preparing a capsule comprising a ground coffee
ingredient.
[0247] The coffee ingredient filled in the capsule can be any
coffee ingredient that can be provided in preferably roast and
ground form. However, it is most preferred for the disclosure of
the present invention throughout that the coffee ingredient is
coffee in any suitable form, such as in the form of coffee beans,
for example roasted coffee beans.
[0248] Thus, the coffee ingredient subjected to the process of the
invention can be coffee, for example coffee beans, which may be
roasted coffee beans.
[0249] The capsule can be any capsule suitable for filling with
coffee ingredients, in particular ground coffee ingredients.
Typically, the capsule comprises a first capsule element and a
second capsule element. Preferably, the capsule is sealable, more
preferably hermetically sealable. According to a preferred
embodiment, the capsule is sealable, or is hermetically sealable,
by sealing engagement of the first and second capsule elements. The
first and second capsule elements can be the same, or can be
different from each other. It is also preferred that the capsule
material or materials exhibit very low gas permeability, or no gas
permeability at all. Most preferably, the capsule is substantially
gas tight, or is gas tight, once sealed or hermetically sealed.
Also, it is very desirable that the capsule is adapted to withstand
comparably high internal pressure, such as an internal pressure of
about 300 mbar to about 500 mbar, about 325 mbar to about 475 mbar,
about 350 mbar to about 450 mbar, about 375 mbar to about 425 mbar
or about 400 mbar. Especially, the pressure is due to the
degasification of the coffee ingredient after sealing of the
capsule. Also, it is preferred that the capsule is adapted for
insertion into a beverage production device. Preferably, the
capsule is adapted to withstand an internal pressure of at least
about 350 mbar, at least about 400 mbar, or at least about 450
mbar, such as about 400 mbar to about 500 mbar, more preferably
about 450 mbar to about 500 mbar. A capsule may be adapted to
withstand internal pressure if it remains intact, e.g. hermetically
sealed, at said pressure.
[0250] The capsule can comprise or can be made of any suitable
material such as, but not limited to, aluminium or a polymer
composition or a combinations thereof. The polymer composition can
be polypropylene or polyethylene. Aluminium is a preferred
material. Preferably, the first element is essentially gas-tight,
preferably, made of aluminium or a polymer composition comprising a
gas barrier, or a laminate of polymer and aluminium.
[0251] Further desirable features and properties of the capsule
elements and capsules will be described below.
[0252] In step (a) of the process, a coffee ingredient is cooled to
a temperature of about -50.degree. C. to about 10.degree. C.
[0253] The coffee ingredient can be cooled to a temperature of
about -45.degree. C. to about 5.degree. C., about -40.degree. C. to
about 0.degree. C., about -35.degree. C. to about -5.degree. C.,
about -30.degree. C. to about -10.degree. C., about -25.degree. C.
to about -15.degree. C., or about -20.degree. C. Preferably, the
coffee ingredient is cooled to a temperature of about -30.degree.
C. to about -10.degree. C., more preferably of about -25.degree. C.
to about -15.degree. C., or about -20.degree. C.
[0254] Cooling step (a) can be performed so that the coffee
ingredient is cooled to the desired temperature comparably fast,
for example within about 30 min or less, within about 20 min or
less, within about 10 min or less, or within about 5 min or less,
from the onset of cooling.
[0255] If the cooling step (a) is preceded by a roasting and/or
tempering step, it is preferred that the cooling step is carried
out quickly (for example, within about 60 min or less, within about
40 min or less, within about 20 min or less, within about 10 min or
less, or within about 5 min or less) after the end of the roasting
step or tempering step.
[0256] However if desired, the coffee ingredient can be stored for
a certain amount of time after cooling down and prior to grinding
step (b). The storing can be at a temperature of about -50.degree.
C. to about 10.degree. C., for example at about -45.degree. C. to
about 5.degree. C., about -40.degree. C. to about 0.degree. C.,
about -35.degree. C. to about -5.degree. C., about -30.degree. C.
to about -10.degree. C., preferably at about -25.degree. C. to
about -15.degree. C., or about -20.degree. C. Storage at
temperatures of about -5.degree. C. to about 10.degree. C., such as
about -3.degree. C. to about 8.degree. C., about 2.degree. C. to
about 7.degree. C., or about 5.degree. C. is likewise contemplated.
The coffee ingredient can for example be stored for at least about
one hour, at least about two hours, at least about five hours or
from about one hour to about 24 hours. After the cooling step, for
example due to operational constraints in case of line stoppage,
the cold beans may be kept stored before grinding between 0 minutes
(=no line stoppage) up to 5 min, up to 30 min, up to 1 hour
depending the unplanned time stoppage. So that when the line
restart after stoppage, the cold beans are fed into the grinder at
the right temperature.
[0257] In the alternative, the grinding step (b) can be performed
after cooling step (a) without storing the coffee ingredient after
cooling step (a).
[0258] In grinding step (b) of the process, which is typically
carried out after cooling step (a), the coffee ingredient is
ground.
[0259] Grinding typically is accompanied by the development of heat
(typically due to the mechanical forces generated by the mill and
coffee). Thus, preferably, the coffee ingredient is cooled during
grinding. The coffee ingredient can be cooled to or maintained at a
temperature of about -50.degree. C. to about 10.degree. C., about
-45.degree. C. to about 5.degree. C., about -40.degree. C. to about
0.degree. C., about -35.degree. C. to about -5.degree. C., about
-30.degree. C. to about -10.degree. C., about -25.degree. C. to
about -15.degree. C., or about -20.degree. C. Preferred are
temperatures of about -5.degree. C. to about 10.degree. C., such as
about -3.degree. C. to about 8.degree. C., or about 2.degree. C. to
about 7.degree. C., about 5.degree. C. being most preferred. A
temperature of about -25.degree. C. to about -15.degree. C., or
about -20.degree. C. is likewise preferred.
[0260] Filling step (c) of the process is typically performed after
grinding step (b). In this step, the coffee ingredient is filled
into a first capsule element. Again, it is preferred that the
coffee ingredient is cooled during this step, to avoid loss of VSs.
Accordingly, the coffee ingredient can be cooled to or maintained
at a temperature of about -50.degree. C. to about 10.degree. C.,
about -45.degree. C. to about 5.degree. C., about -40.degree. C. to
about 0.degree. C., about -35.degree. C. to about -5.degree. C.,
about -30.degree. C. to about -10.degree. C., about -25.degree. C.
to about -15.degree. C., or about -20.degree. C. in step (c).
Preferred are temperatures of about -5.degree. C. to about
10.degree. C., such as about -3.degree. C. to about 8.degree. C.,
or about 2.degree. C. to about 7.degree. C., about 5.degree. C.
being most preferred. A temperature of about -25.degree. C. to
about -15.degree. C., or about -20.degree. C. is likewise
preferred.
[0261] In a further step, step (d), the first capsule element is
hermetically sealed with a second capsule element. As a result, the
first and second capsule elements are connected with one another
and may form a completely closed capsule. The connection formed by
hermetically sealing may be complete and substantially air tight,
or air tight. More preferably, the connection is preferably gas
tight. The hermetically sealing may comprise welding and/or
crimping.
[0262] Again, it is preferred that the coffee ingredient is cooled
during this step. Thus, the coffee ingredient can be cooled to or
maintained at a temperature of about -50.degree. C. to about
10.degree. C., about -45.degree. C. to about 5.degree. C., about
-40.degree. C. to about 0.degree. C., about -35.degree. C. to about
-5.degree. C., about -30.degree. C. to about -10.degree. C., about
-25.degree. C. to about -15.degree. C., or about -20.degree. C. in
step (d). Preferred are temperatures of about -5.degree. C. to
about 10.degree. C., such as about -3.degree. C. to about 8.degree.
C., or about 2.degree. C. to about 7.degree. C., about 5.degree. C.
being most preferred. A temperature of about -25.degree. C. to
about -15.degree. C., or about -20.degree. C. is likewise
preferred.
[0263] Albeit not required, the process may comprise one or more
additional steps.
[0264] For example, the process may further comprise step (a)', in
which the coffee ingredient is roasted. The conditions applied
during roasting are not particularly limited and may be as known in
the art. If the process encompasses roasting step (a)', step (a)'
is performed prior to step (a).
[0265] In other words, according to some embodiments, step (a) may
not be the initial step of the process according to the
invention.
[0266] In the alternative or in addition, the process may further
comprise step (a)'', in which tempering of the coffee ingredient is
performed. Tempering aims at homogenising the water content of the
coffee ingredient. It can be performed by storing the coffee
ingredient for a given amount of time (such as of 60 to 80 minutes)
generally under ambient temperature and under modified atmosphere
(e.g. saturated with nitrogen gas).
[0267] If the process comprises tempering step (a)'', said step is
performed prior to step (a). In embodiments where the process
encompasses both, step (a)' and step (a)'', step (a)'' can be
performed after step (a)' and prior to step (a).
[0268] In the alternative or in addition, the process may further
comprise step (c)', wherein the coffee ingredient is compressed or
normalized. Generally, the coffee ingredient is beaten or
mixed/homogenised to obtain the right density (e.g., 420 g/L for
5.5 g of coffee ingredient) and then the capsule is filled in with
the right weight of coffee ingredient.
[0269] Again, it is desirable that the coffee ingredient is cooled
during this step. Accordingly, the coffee ingredient can be cooled
to or maintained at a temperature of about -50.degree. C. to about
10.degree. C., about -45.degree. C. to about 5.degree. C., about
-40.degree. C. to about 0.degree. C., about -35.degree. C. to about
-5.degree. C., about -30.degree. C. to about -10.degree. C., about
-25.degree. C. to about -15.degree. C., or about -20.degree. C. in
step (c)'. Preferred are temperatures of about -5.degree. C. to
about 10.degree. C., such as about -3.degree. C. to about 8.degree.
C., or about 2.degree. C. to about 7.degree. C., about 5.degree. C.
being most preferred. A temperature of about -25.degree. C. to
about -15.degree. C., or about -20.degree. C. is likewise
preferred.
[0270] Typically, step (c)' is performed after step (b) and prior
to step (c).
[0271] Certain coffee ingredients, such as for example coffee, are
typically processed by methods that encompass a degasification
step, in particular after the coffee ingredient has been ground.
Due to the enlarged ingredient surface formed as a result of
grinding, degasification is typically allowed for after grinding.
During degasification, the emission of carbon gas (CO.sub.2 and CO)
developing due to the roasting process from ground coffee
ingredient is allowed for.
[0272] Accordingly, in the alternative or in addition, the process
according to the present invention may further comprise step (c)'',
degasification of the coffee ingredient. Step (c)'' can be
performed after step (b) and prior to step (c), or after step (c)'
and prior to step (c).
[0273] It should be noted that according to typical methods of the
prior art, the degasification step is performed at ambient
temperature and requires considerable amounts of time, and may take
up to 72 hours or even longer. However, the prior art has paid
little attention to the significance of this step in relation with
oxidation processes and loss of VSs from the coffee product.
[0274] The present inventors found the quality of the obtained
coffee product to be even further improved when the time between
the end of the grinding step and the hermetically sealing of the
capsule was reduced. Accordingly, in a preferred embodiment of the
process according to the present invention, the time between the
end of the grinding step and the hermetically sealing of the
capsule is reduced, e.g. is reduced to less than about 180 min,
less than about 150 min, less than about 120 min, less than about
90 min, less than about 60 min, less than about 45 min, less than
about 30 min or even less than 20 min.
[0275] In particular, the present inventors have also found that a
reduction in the duration of the degasification step (c)''
advantageously reflects on the quality of the obtained product,
since oxidization processes and loss of VSs, such as VOCs, is
reduced. Without wishing to be bound by theory, the inventors have
found that the carbon gas (CO.sub.2, CO) emitted from the coffee
ingredient during the degasification step comprises large amounts
of VSs. The reduction of the processing times from the end of the
grinding step to the hermetically sealing of the capsule was found
to significantly decrease the loss of VSs due to emission of carbon
gas A reduction in the duration of the degasification step itself
has been found particular useful, especially when combined with
maintaining the coffee product at comparably cool temperatures
during the degasification step.
[0276] Accordingly, it is preferred that the degasification step
(c)'', if present, is performed for about 40 min or less, for about
35 min or less, for about 30 min or less, for about 25 min or less,
for about 20 min or less, for about 15 min or less, for about 10
min or less, or for about 5 min or less. More preferably, the
duration of step (c)'' is about 35 min to about 5 min, most
preferably about 20 min to about 10 min.
[0277] Likewise, it has been found that cooling the coffee
ingredient during degasification further helps to retain VSs and to
reduce oxidation processes. Accordingly, it is preferred that the
coffee ingredient in step (c)'' is cooled. More preferably, the
coffee ingredient is cooled to or maintained at a temperature of
about -50.degree. C. to about 10.degree. C., about -45.degree. C.
to about 5.degree. C., about -40.degree. C. to about 0.degree. C.,
about -35.degree. C. to about -5.degree. C., about -30.degree. C.
to about -10.degree. C., about -25.degree. C. to about -15.degree.
C., or about -20.degree. C. in step (c)''. Preferred are
temperatures of about -5.degree. C. to about 10.degree. C., such as
about -3.degree. C. to about 8.degree. C., or about 2.degree. C. to
about 7.degree. C., about 5.degree. C. being most preferred. A
temperature of about -25.degree. C. to about -15.degree. C., or
about -20.degree. C. is likewise preferred.
[0278] Reduction in duration of step (c)'' and cooling, as detailed
above, can advantageously be applied in combination.
[0279] As already indicated above, the coffee ingredient can be
cooled in one or more steps of the process according to the present
invention. Also, the coffee ingredient can be maintained at a
certain temperature in one or more steps of the process according
to the present invention. While apart from cooling step (a),
cooling is not required, it is nevertheless preferred that the
coffee ingredient is cooled in at least one of steps (b), (c), (d),
and--insofar as present--(c)' and (c)''. More preferably, the
coffee ingredient is cooled in all of these steps. Even more
preferably, the coffee ingredient is maintained at a temperature of
about -50.degree. C. to about 10.degree. C. in at least one of
steps (b), (c), (d), and--insofar as present--(c)' and (c)''. More
preferably, the coffee ingredient is maintained at a temperature of
about -50.degree. C. to about 10.degree. C. in all of these steps.
The temperature may be chosen independently for each step.
[0280] Means for cooling and/or maintaining a coffee ingredient at
a desired temperature that can be applied in the process according
to the present invention are readily available to the skilled
person. For example, and without limitation, cooling and/or
maintaining of the coffee ingredient at the desired temperature can
be achieved by cold inert substances, such as liquid nitrogen or
solid carbon dioxide. These substances can be brought in direct
contact with the coffee ingredient, or can be provided in a closed
system that is in contact with or in proximity to the coffee
ingredient. A fan or similar equipment can be used to remove
evaporating gas, such as evaporating liquid nitrogen, from the
coffee ingredient or the system if desired.
[0281] In the alternative or in addition, freezing devices can be
used, such as blast freezers, spiral freezers or tunnel freezers.
Likewise, cooling units such as water cooling units can be used.
Also, cooling can be achieved by circulation of a cold fluid inside
double jacketed equipment. A cooling fluid can be circulated in the
water circuit of the grinder, the normalizer used for compacting
and/or the degasing unit.
[0282] While cold temperatures during the degasification step and
reduction of the degasification time were found to work well, best
effects where obtained when the degasification step was omitted
entirely from the process according to the invention. Thus,
according to one aspect, the present process does not comprise a
long degasification step (c)'', or does not comprise any
degasification step (i.e. neither comprises a step (c)'' as
detailed above nor any other dedicated degasification step).
[0283] Besides advantages relating to the quality of the obtained
product, reduced processing times improve the efficacy of the
entire process. Thus, reduced processing times, in particular
reducing the duration of the degasification step or omitting said
step entirely, offer clear advantages, especially when combined
with maintaining the coffee product at comparably cool temperatures
during some or all steps of the process.
[0284] Yet, emission of carbon gas from the coffee ingredient
during filling, sealing and even thereafter, is a further effect of
the reduced processing times that is particularly pronounced if the
time allowed for the degasification step is reduced, degasification
is carried out while maintaining the product at cold temperatures,
or the process does not comprise any degasification step at
all.
[0285] On the one hand, the emitted gas advantageously helps to
further reduce oxidation processes that may occur in the coffee
ingredient, because the contact of the oxygen comprised in the
surrounding atmosphere with the coffee ingredient is minimized and
the emitted gas builds a less oxidizing atmosphere in the sealed
capsule. This may abolish the need for inert gas to create a
non-oxidizing atmosphere during processing steps and also within
the capsule. Yet, inert gas, such as nitrogen, can nevertheless be
used if desired.
[0286] On the other hand however, the emission of gas in the sealed
capsule may result in an elevated pressure within the capsule,
especially if the capsule is hermetically sealed. However,
hermetically sealing of the capsule is highly desirable to avoid
the eventual loss of VSs along with CO.sub.2 escaping from the
capsule, to avoid the exposure to oxygen entering the capsule and
for general hygiene considerations.
[0287] The elevated pressure occurring is especially problematic in
capsules adapted for insertion into and/or use with a beverage
production device. Many of these devices rely on the interaction of
a coffee ingredient provided in a capsule with a liquid, such as
hot water, that enters the capsule under pressure, for example
through a slit or the like in the capsule created in the beverage
production device. To retrieve the liquid from the capsule, the
capsule is typically adapted to allow for the opening of the
capsule upon injection of a pressurized liquid during machine
extraction, e.g. by tearing or disruption of a capsule element,
such as a membrane.
[0288] Generally, since the capsule comprises a capsule element,
such as a membrane, intended to be torn under liquid pressure in
the machine during extraction, the capsule element can burst and
break or delaminate if a too high pressure of gas is created in the
capsule during storage. This can be the case if a coffee
ingredient, such as coffee is not or not sufficiently degased
before the filling and sealing steps and therefore coffee produces
gas in the sealed capsule.
[0289] The possibilities of making such a capsule more pressure
resistant by simply providing a thicker and/or stronger material
are limited, because otherwise, the capsule would no longer open
readily upon injection of a pressurized liquid.
[0290] Thus, according to one aspect, the present invention
provides for the use of a first and second capsule element in the
process according to the present invention, wherein the first
capsule element comprises a rim for sealing engagement with the
second capsule element, and further comprises at least one
sidewall, and a bottom wall. The first capsule element can for
example comprise one, at least two, at least three, at least four,
at least five, or at least ten sidewalls. It may be preferred that
the first capsule element comprises one sidewall such as a
frusto-conical sidewall.
[0291] The at least one side wall and the bottom wall define an
interior chamber having an opening. The opening spans a plane. The
rim of the first capsule element preferably extends outwards from
the sidewall and surrounds the opening. Most preferably, the rim is
bent into the direction of the bottom wall, the rim and the plane
forming an angle of at least about 10.degree., preferably at least
about 12.degree.. The angle formed may be about 10.degree. to about
31.degree., about 10.degree. to about 28.degree., about 12.degree.
to about 26.degree., about 14.degree. to about 24.degree., about
16.degree. to about 22.degree., or about 18.degree. to about
20.degree.. The angle can be 10.degree., 11.degree., 12.degree.,
13.degree., 14.degree., 15.degree., 16.degree., 17.degree.,
18.degree., 19.degree., 20.degree., 21.degree., 22.degree.,
23.degree., 24.degree., 25.degree., 26.degree., 27.degree.,
28.degree., 29.degree., or 30.degree.. Preferably, the angle is
about 12.degree. to about 28.degree., such as about 16.degree. to
about 28.degree., or about 18.degree. to about 26.degree.. Even
more preferred are angles of about 20.degree. to about 28.degree.,
such as about 22.degree. to about 26.degree., or about
24.degree..
[0292] The rim can be pre-bent, and thus present before a sealing
engagement between the first capsule element and a further capsule
element occurs.
[0293] The rim of the first capsule element can comprise a flat
annular part. The rim of the first capsule element may be a
flange-like rim. The rim of the first capsule element may be a
flange-like rim comprising a flat annular part.
[0294] The angle can be determined prior to the sealing connection
of the first capsule element with the second capsule element, for
example on the first capsule element taken in isolation, in
particular if the rim is a pre-bent rim.
[0295] The sealing connection between the first capsule element and
the second capsule element, e.g., membrane, is preferably provided
on the flat annular part.
[0296] Without wishing to be bound by theory, the present inventors
have found that surprisingly, the angle between the rim and the
plane of the opening attributes increased pressure resistance to
the hermetically sealed capsule obtained by sealing the first and
second capsule elements in step (d) of the process according to the
invention.
[0297] The first capsule element may be a capsule body.
[0298] According to a preferred embodiment, the first capsule
element is rotationally symmetric and/or is of essentially
frusto-conical shape, or frusto-conical shape. The sealing
connection of the second capsule element with the rim preferably
extends, from the inner sealing point to the outer sealing point,
along a rectilinear direction, when the capsule is viewed in
cross-sectional view. As result, the resistance to any delamination
(including any initiation of delamination) of the membrane, is
increased.
[0299] Preferably, the second capsule element is a membrane. The
membrane can have a thickness about 30 .mu.m to about 40 .mu.m. The
membrane is preferably impermeable for air (CO.sub.2, CO, O2, N2, .
. . ) and coffee aroma volatiles, i.e., gas-tight. The membrane can
comprise or consist of any suitable material, such as aluminium or
a multi-layer comprising the following layers (from exterior to
interior): PET/Colour layer/Adhesive/Aluminium/Adhesive/OPP.
[0300] Capsule elements and capsules useful in the process
according to the present invention will be described in even
further detail below.
[0301] According to a further aspect, a vacuum or a reduced
pressure can be applied to the first capsule element. Thus, a
partial vacuum or reduced pressure can be created within the
capsule by providing a negative pressure before fully sealing the
capsule. This way, the coffee ingredient, such as coffee, in the
capsule is given the capacity to release carbon gas while
maintaining the pressure inside the capsule sufficiently low.
[0302] A vacuum or a reduced pressure can be applied to the first
capsule element or capsule after filling the ground coffee
ingredient into the first capsule element and before the first
capsule element is entirely hermetically sealed with the second
capsule element. The reduced pressure applied to the first capsule
element can be about 100 mbar to about 800 mbar under atmospheric
pressure, such as about 200 mbar to about 700 mbar, about 300 mbar
to about 600 mbar, or about 400 mbar to about 500 mbar under
atmospheric pressure. It is preferred that the reduced pressure
applied is about 600 mbar to about 800 mbar, such as about 650 mbar
to about 750 mbar, or about 700 mbar to about 770 mbar under
atmospheric pressure. In normal conditions, the atmospheric
pressure can be generally about 1013.25 mbar (+/-100).
[0303] The reduced pressure can be applied prior to step (d) and/or
during sealing step (d). The vacuum or reduced pressure can be
applied after filling step (c) and prior to sealing step (d).
[0304] The vacuum or reduced pressure can be applied after filling
step (c) and during sealing step (d). The vacuum or reduced
pressure may be applied at some point during step (d), before the
hermetically sealing is fully completed.
[0305] During application of the vacuum or reduced pressure, the
coffee ingredient can be cooled, and/or can be maintained at a
certain temperature, as desired. For example, the coffee ingredient
can be cooled to or maintained at a temperature of about
-50.degree. C. to about 10.degree. C., about -45.degree. C. to
about 5.degree. C., about -40.degree. C. to about 0.degree. C.,
about -35.degree. C. to about -5.degree. C., about -30.degree. C.
to about -10.degree. C., preferably about -25.degree. C. to about
-15.degree. C., or about -20.degree. C. Temperatures of about
-5.degree. C. to about 10.degree. C., such as about -3.degree. C.
to about 8.degree. C., about 2.degree. C. to about 7.degree. C., or
about 5.degree. C. are also preferred.
[0306] Preferred means for applying a vacuum or a reduced pressure
that can be used for applying a vacuum or a reduced pressure to a
capsule element or capsule are described in co-pending patent
application PCT/EP13/063174.
[0307] By applying a vacuum or a reduced pressure, the emission of
gas in the hermetically sealed capsule can be partially or entirely
compensated for. In other words, the increase of pressure in the
capsule due to the emanation of carbon gas from the coffee
ingredient can be substantially equal to the reduction of pressure
applied before sealing step d).
[0308] The skilled person understands that both aspects useful to
compensate for the emission of gas in the capsule can be used in
combination. Hence, the invention also provides for the application
of a vacuum or reduced pressure when a first capsule element
comprising a rim for sealing engagement with the second capsule
element is used, the capsule element further comprising at least
one sidewall, and a bottom wall, the side wall and the bottom wall
defining an interior chamber having an opening, the opening
spanning a plane, the rim of the first capsule element extending
outwards from the sidewall and surrounds the opening, the rim being
bent into the direction of the bottom wall, the rim and the plane
of the opening forming an angle of at least about 10.degree.,
preferably of at least about 12.degree..
[0309] FIG. 1 shows an exemplary, non-limiting example of a process
according to the invention. According to the exemplary process of
FIG. 1, a coffee ingredient that is roasted coffee beans is
provided as starting material. The process starts with step 1,
tempering of the coffee beans. In a second step 2, the tempered
coffee beans are cooled with liquid nitrogen. Optionally,
N.sub.2-gas is exhausted 3. This can be done by using a fan or the
like. The cooled beans are subsequently subjected to grinding step
4, followed by normalizing or compacting step 6, degassing step 8,
and filling step 10. Steps 4, 6, and 8 are carried out while
maintaining the coffee ingredient cold. To that end, cooling units
5, 7 and 9 are used for steps 4, 6 and 8, respectively.
[0310] FIG. 2 shows a further exemplary, non-limiting example of a
process according to the invention. Coffee beans are the coffee
ingredient that is used as starting material. The process
optionally starts with a roasting step. The roasted beans are
transferred for tempering under N.sub.2-flushing, or the beans are
cooled to a temperature of about -20.degree. C. under ambient air,
to provide pre-cooled roasted coffee beans. The pre-cooled coffee
beans are then subjected to grinding, followed by a
normalizing/compacting step, degasification step, and the steps of
filling into capsules and sealing. The grinding step can be
performed under ambient air or under cooled conditions such as
under N2-flushing, while the normalizing/compacting step, the
degasification step, and the steps of filling and sealing are
performed under N.sub.2-flushing. A cooling unit provides a cooling
fluid such as a mixture of water and glycol for a cooling circuit
during grinding, normalizing/compacting, and degasification.
[0311] Capsule Elements and Capsules According to the Invention
[0312] The present invention also provides for a capsule obtainable
by a process according to the invention. The capsule comprises a
ground coffee ingredient, and preferably comprises ground coffee.
Most preferably, the capsule is adapted for insertion into a
beverage producing unit. The capsule can be a capsule comprising a
membrane as the second capsule element. The capsule can comprise a
single serving of the ground coffee ingredient, such as the ground
coffee.
[0313] A capsule obtainable by a process according to the invention
can be distinguished from capsules of the prior art in one or more
of the following aspects.
[0314] For example, a capsule obtainable by a process according to
the invention can comprise a ground coffee ingredient that has a
higher content of one or more VSs, such as VOCs, than a capsule
comprising a ground coffee ingredient obtainable by a process
according to the prior art, when the same coffee ingredient is used
as a starting material and the same amount of ground coffee
ingredient is comprised within the capsule.
[0315] Absolute and/or relative contents in the ground coffee
ingredient, such as ground coffee of one or more VSs, such as VOCs,
can be higher for a capsule obtainable by a process according to
the present invention. Also, a capsule obtainable by a process
according to the present invention can comprise more of one or more
VSs, such as VOCs, relative to a capsule comprising a ground coffee
ingredient obtainable by a process according to the prior art, when
the same coffee ingredient is used as a starting material.
Non-limiting examples of VSs that can be determined can be selected
from the group consisting of thiols, sulfides, Strecker aldehydes,
diketones, pyrazines, phenols or a combination thereof.
[0316] The aroma in cup of coffee prepared from a capsule
obtainable by a process according to the invention was found to be
increased by +20% to +30% (compared to the same capsule without the
process of the invention as considered as a reference), and the
aroma above the cup was found to be increased by +35% to +70%
compared to a capsule prepared according to the process of the
prior art wherein neither cooling nor reduced or eliminated
degasing times were applied.
[0317] In the alternative or in addition, a capsule obtainable by a
process according to the invention can be characterized by a higher
pressure, and/or a higher content or concentration of carbon gas
within the capsule than a capsule comprising a ground coffee
ingredient obtainable by a process according to the prior art, when
the same coffee ingredient is used as a starting material, and the
same amount of ground coffee ingredient is comprised within the
capsule.
[0318] Likewise in the alternative or in addition, a capsule
according to the invention can be distinguished from a capsule of
the prior art by the presence of a specific angle between a rim of
a first capsule element having an opening and a plane of the
opening. In particular, the capsule can be a capsule comprising a
first capsule element, the first capsule element comprising a rim
for sealing engagement with a second capsule element, at least one
sidewall, and a bottom wall, wherein the at least one side wall and
the bottom wall define an interior chamber having an opening, the
opening spanning a plane, wherein further the rim extends outwards
from the sidewall and surrounds the opening, the rim being bent
into the direction of the bottom wall, the rim and the plane of the
opening forming an angle of at least about 10.degree., preferably
at least about 12.degree..
[0319] The present invention also provides for a capsule element
for a capsule comprising a ground coffee ingredient, wherein the
capsule element comprises a rim for sealing engagement with a
second capsule element, at least one sidewall, and a bottom
wall.
[0320] The capsule element can for example comprise one, at least
two, at least three, at least four, at least five, or at least ten
sidewalls. It is preferred that the first capsule element comprises
one sidewall, preferably a frusto-conical sidewall.
[0321] The at least one side wall and the bottom wall define an
interior chamber having an opening. The rim extends outwards from
the sidewall and surrounds the opening. The opening spans a plane.
The rim is preferably bent into the direction of the bottom wall.
This means that the angle fainted by the rim and the sidewall(s) is
acute or lower than 90.degree..
[0322] The rim and the plane of the opening form an angle of at
least about 10.degree., preferably at least about 12.degree.. The
angle formed may be about 10.degree. to about 31.degree., about
10.degree. to about 28.degree., about 12.degree. to about
26.degree., about 14.degree. to about 24.degree., about 16.degree.
to about 22.degree., or about 18.degree. to about 20.degree.. The
angle can be 10.degree., 11.degree., 12.degree., 13.degree.,
14.degree., 15.degree., 16.degree., 17.degree., 18.degree.,
19.degree., 20.degree., 21.degree., 22.degree., 23.degree.,
24.degree., 25.degree., 26.degree., 27.degree., 28.degree.,
29.degree., or 30.degree.. Preferably, the angle is about
12.degree. to about 28.degree., such as about 16.degree. to about
28.degree., or about 18.degree. to about 26.degree.. Even more
preferred are angles of about 20.degree. to about 28.degree., such
as about 22.degree. to about 26.degree., or about 24.degree..
[0323] The rim can be pre-bent, and thus be present before a
sealing engagement between the capsule element and a further
capsule element occurs.
[0324] The angle can be determined prior to the sealing connection
of the capsule element with the second capsule element, for example
on the capsule element taken in isolation, in particular if the rim
is a pre-bent rim.
[0325] The rim of the capsule element can comprise a flat part,
preferably annular. The rim of the capsule element can be a
flange-like rim. The rim of the capsule element can be a
flange-like rim comprising a flat annular part and a curled
flange.
[0326] The angle between the rim and the plane of the opening can
be determined by the level between two points placed on a flat part
of the rim.
[0327] The angle between the plane of the opening and the rim can
be the angle between the plane of the opening and a straight line
passing through two points on the rim, preferably on a flat part of
the rim, wherein the two points are points of intersection of a
second plane and the rim, the second plane being a plane passing
through the centre of the opening and being orthogonal to the plane
of the opening.
[0328] The flat part of the rim constitutes all or part of the
sealing connection for the second capsule element with the first
capsule element. As a result, the resistance to delamination is
obtained solely by the inclination of the rim at the flat part and
is not obtained by other means, such as a preformed recess in the
lower face of the rim for providing a wedge effect, and/or a
partial delamination providing a reserve for an excess of gas.
[0329] Capsules comprising a capsule element according to the
invention can withstand a higher internal capsule pressure. This is
particularly true for embodiments where the second capsule element
is a membrane, especially where the membrane is comparably thin, as
the case may be for capsules adapted for insertion into and/or use
with a beverage production device. The present inventors have found
that upon increased internal capsule pressure, the membrane deforms
outwardly to form, ultimately followed by bursting and/or
delamination of the membrane from the first capsule element.
However, if a capsule element having a rim as described above is
used as the first capsule element, the membrane periphery aligns in
the direction of the inclined rim when forming a dome. The
orthogonal force component is so lower making the strength against
delamination of the membrane on the rim much higher.
[0330] The rim of the capsule element may be a flange-like rim.
[0331] The sidewall of the capsule element can have an upper and a
lower end, the upper end defining a circle having a first diameter,
the lower end defining a circle having a second diameter, wherein
the opening is located at the upper end. The second diameter can be
smaller than the first diameter. The bottom wall can be located at
the lower end. The bottom wall can be located opposite the
opening.
[0332] The capsule element can be a capsule body. In the
alternative or in addition, the capsule element can be rotationally
symmetric or a combination thereof. Preferably, the capsule element
is of essentially frusto-conical shape or of frusto-conical
shape.
[0333] The capsule element is formed of a substantially gas-tight,
gas tight material. The capsule element can comprise or can be made
of any suitable material such as, but not limited to, aluminium or
a polymer composition. The polymer composition can be polypropylene
or polyethylene bur preferably comprises a gas barrier layer such
as EVOH. Aluminium is a preferred material. A laminate of polymer
and aluminium is possible such as aluminium-PP.
[0334] The capsule element can further comprise a sealing means.
The sealing means can be applied to or connected with the rim of
the capsule element, so as to allow sealing engagement with a
further capsule element, which may be different from the first
capsule element. The sealing means can be a sealing lacquer and the
like.
[0335] It is highly preferred that the capsule element according to
the present invention is a capsule element for preparing a
beverage, such as coffee. Even more preferred is that the capsule
element is adapted for insertion into and/or use with a beverage
production device.
[0336] A schematic drawing of one embodiment of an exemplary
capsule according to the invention is shown in FIG. 3. The capsule
shown in FIG. 3 is preferred; however, the skilled person
understands that the invention is not limited thereto.
[0337] The present invention further provides for a capsule
comprising as a first capsule element a capsule element according
to the invention, the capsule further comprising a second capsule
element for sealing connection with the rim of the first capsule
element. The sealing means can be a sealing lacquer and the
like.
[0338] The second capsule element may be in a sealing connection or
a hermetically sealing connection with the rim of the first capsule
element. Optionally, the sealing or hermetically sealing connection
may be mediated by a sealing means located between the rim of the
first capsule element and the adjacent part of the second capsule
element. The hermetically sealing connection is substantially
gas-tight, or is gas tight.
[0339] According to a preferred embodiment, the second capsule
element is a membrane. The membrane may have a thickness of about
30 .mu.m to about 40 .mu.m, such as about 33 .mu.m to about 37
.mu.m, or about 35 .mu.m. The membrane may be embossed in which
case the thickness is regarded as the thickness of the membrane as
it was non-embossed and free of lacquer. In the alternative or in
addition, the membrane may be impermeable, or substantially
impermeable for CO.sub.2. Preferably, the membrane is substantially
gas-tight, or is gas tight. The membrane can comprise or consist of
any suitable material, such as aluminium.
[0340] The capsule may comprises a coffee ingredient most
preferably roast and ground coffee.
[0341] The pressure within the capsule may be about 300 mbar to
about 500 mbar, about 325 mbar to about 475 mbar, about 350 mbar to
about 450 mbar, about 375 mbar to about 425 mbar or about 400
mbar.
[0342] The pressure within the capsule can be determined manually
by putting the capsule into a pressure controlled box. The pressure
is varied until the absolute internal pressure of the capsule
(mbar) is equivalent to the absolute pressure in the box (mbar);
when the membrane of the capsule becomes floppy at this point. The
internal pressure is considered as equal to the absolute pressure
in the box and the relative pressure of the capsule is given by the
absolute pressure according to the atmospheric pressure. The
pressure within the capsule can be a pressure determined after 7
days of storage under ambient (20.degree. C.) conditions.
[0343] It is highly preferred that the capsule according to the
present invention is a capsule for preparing a beverage, such as
coffee. Even more preferred is that the capsule is adapted for
insertion into and/or use with a beverage production device.
Accordingly, the capsule may be adapted to allow for the opening of
the capsule upon injection of a pressurized liquid, e.g. by tearing
or disruption of a capsule element, such as a membrane.
[0344] It is even more preferred that capsule is a capsule
comprising a single serving of ground coffee (e.g., from 5 g-12 g
of ground coffee). Most preferably, this capsule is an hermetically
or gas-tightly sealed capsule.
[0345] The capsule can be stored at a wide range of temperatures,
such as from about -30.degree. C. to about 50.degree. C., such as
from about -20.degree. C. to about 40.degree. C., or from about
-10.degree. C. to about 30.degree. C., or about 0.degree. C. to
about 20.degree. C.
[0346] A schematic drawing of one embodiment of an exemplary
capsule according to the invention is shown in FIG. 3. The capsule
shown in FIG. 3 is preferred; however, the skilled person
understands that the invention is not limited thereto.
[0347] FIG. 3A shows a schematic side-view of the capsule. The
capsule comprises a first capsule element 21 that is of essentially
frusto-conical shape and has a side-wall 22 and a bottom wall 23,
the side wall and the bottom wall defining an interior chamber 24
having an opening 25. Element 21 comprises a flange-like rim 26
comprising a flat part 27 and a preferably curled flange 28. The
capsule further comprises a second capsule element 30 that is a
membrane. It is apparent that the membrane is sealed on a portion
(at least) of the flat part 27, without any recess being formed in
the rim in this sealed region. Therefore, the start of the
delamination is not promoted.
[0348] The flat part of the rim 26 and a plane P spanned by the
opening 25 form an angle A of about 12.degree., as can be seen in
more detail in FIG. 3C.
[0349] FIG. 3B shows additional views of capsule element 21.
EXAMPLES
[0350] The following examples are not to be construed as
limiting.
Example 1
[0351] A capsule comprising ground coffee was prepared, as
schematically depicted in FIG. 1.
[0352] Initially, coffee beans were roasted, followed by storing in
the existing tempering silo or storage at -20.degree. C. Then,
beans were fed into the cryogenic equipment. Liquid nitrogen was
injected inside the cryogenic equipment, where the beans are in
direct contact with the liquid nitrogen. In direct contact with the
beans, the liquid nitrogen cools down the beans to the setup
temperature value. The beans temperature at the exit of the
cryogenic equipment can be adjusted by the ratio between the amount
of beans and of liquid nitrogen inside the cryogenic equipment and
by the residence time of the beans inside the cryogenic
equipment.
[0353] A fan can optionally be used to exhaust to the outside the
N.sub.2-gas expanded from the liquid nitrogen evaporation (or to
recirculate gas to the grinder for example). The cold beans were
fed into the grinder. The grinder rolls were cooled by circulation
of a cooling fluid (additionally or alternatively, liquid nitrogen
could be injected inside the grinder to contact the coffee
ingredient). Then, the roasted and ground coffee was compacted by
adjustment of the normalizer head opening. The normalizer double
jacket was cooled by circulation of a cooling fluid. The coffee is
degassed in the degasing unit. This can be done by adjusting the
coffee load. The degasing unit double jacket was likewise cooled by
circulation of a cooling fluid. Finally, the roasted and ground
coffee was dosed in capsules in the filling line. In a possible
alternative, the coffee ingredient could be cooled inside the
filling line and dosing unit with indirect cooling such as by using
a double jacket circuit, or with direct injection of liquid
nitrogen. Also due to operational constraints and to avoid coffee
aroma loss during the temporary line stoppage, additional equipment
may be required to maintain the coffee cold during such
interruptions.
Example 2
[0354] The aroma of capsules comprising ground coffee prepared
according to a process of the invention was evaluated. The process
is the one described in Example 1.
[0355] To that end, the in-cup aroma and the in-room aroma of the
capsules was analyzed as outlined below.
[0356] Experimental Setup
[0357] a) In-Cup Coffee Odorant Analysis:
[0358] Absolute contents (ppm/g roasted and ground coffee) of key
coffee odorants (thiols, sulfides, Strecker aldehydes, diketones,
pyrazines and phenols) were determined in-cup using the
corresponding isotopic labelled standards in conjunction with
SPME/GC/MS (Solid Phase Micro Extraction fiber with Gas
Chromatography combined with Mass Spectrometer detector). The
coffee odorants were extracted from the roast and ground by
weighing 4 g roast and ground (taken from different freshly opened
capsules) in 100 mL boiling water and leaving the suspension to
extract for 15 min under continuous stirring using a magnetic
stirring bar. Every sample was extracted and measured in
triplicate. The analysis was split into two groups of analytes.
[0359] Group 1 (Analysis of Thiols, Sulfides and Pyrazines)
[0360] After extraction, the coffee samples were quickly cooled on
ice and 100 mg of cysteine was added to the coffee samples to avoid
thiol binding to the coffee matrix during sample work up. Definite
amounts of isotope labeled standards were added and the solutions
were stirred for 10 min. Subsequently, portions of 7 mL were
transferred to headspace vials.
[0361] After an equilibration (40.degree. C., 1 min), the aroma
compounds were extracted from the headspace during 10 min at
40.degree. C. under agitation (350 rpm) using a
divinylbenzene-carboxen-polydimethylsiloxane SPME fiber (StableFlex
DVB/CAR/PDMS; 2 cm; film thickness 50/30 .mu.m; Supelco, Buchs,
Switzerland). The extracted compounds were thermally desorbed for 3
min into a split/splitless injector maintained at 240.degree. C.
and operated in splitless mode. For separation of compounds, an
Agilent 7890A gas chromatograph (Agilent Technologies, Morges,
Switzerland) with a 60 m.times.0.25 mm.times.0.25 .mu.m DB-Wax
column was used (Agilent Technologies, Morges, Switzerland). Helium
was used as a carrier gas with a constant flow of 1.3 mL/min, and
the following temperature program was applied: 40.degree. C. (6
min), 4.degree. C./min, 140.degree. C. (0 min), 20.degree. C./min,
240.degree. C. (10 min). The gas chromatograph was coupled to a
5975C mass spectrometer (Agilent Technologies, Morges, Switzerland)
operating in single ion monitoring (SIM) mode using electron
ionization and an ionization potential of 70 eV. All GC-MS
measurements were run in triplicate. Data were analysed using the
MassHunter Quant software (Version B.05.02, Agilent
Technologies).
[0362] Group 2 (Strecker Aldehydes, Diketones and Phenols)
[0363] After cooling the coffee samples on ice and diluting until a
final volume of 100 mL, a 4:1 additional dilution was performed.
Definite amounts of isotope labeled standards were added and the
solutions were stirred for 10 min. Portions of 7 mL were
transferred to headspace vials.
[0364] The coffee volatiles were extracted and injected into a
Thermo Trace Ultra gas chromatograph (Brechbuhler, Schlieren,
Switzerland) as described above for Group 1. In contrast to Group
1, volatiles were separated on a 60 m.times.0.25 mm.times.1.4 .mu.m
DB-624 column (Agilent Technologies, Morges, Switzerland). Helium
was used as a carrier gas with a constant flow of 1.3 mL/min, and
the following temperature program was applied: 40.degree. C. (6
min), 6.degree. C./min, 140.degree. C. (0 min), 20.degree. C./min,
240.degree. C. (10 min). The gas chromatograph was coupled to a
Thermo Scientific ISQ mass spectrometer (Brechbuhler, Schlieren,
Switzerland) operating in single ion monitoring (SIM) mode using
electron ionization and an ionization potential of 70 eV. All GC-MS
measurements were run in triplicate. Data were analysed using the
Xcalibur 2.1 software (Thermo Scientific).
[0365] Samples which were produced according to a process of the
present invention were compared to the corresponding reference
sample.
[0366] b) Around Machine Coffee Odorant Analysis (Method Using
Tenax-GC-MS):
[0367] The amount of aroma released around a coffee machine (in
microgram) was measured in a hermetically closed glovebox, having
electricity supply and containing the coffee machine. Coffees were
prepared inside the glovebox using the capsule/machine
configuration, using a Nespresso "U" (trademark) machine. A similar
preparation was done for reference and samples treated with
cryogenic equipment. A representative air sample (225 ml) was
sampled from this glovebox directly after beverage preparation. The
coffee aroma was trapped onto a Tenax trap (Markes International,
Llantrisant, UK), involving a tube packed with Tenax TA adsorbent
resin to trap the volatiles passing through the tube. The Tenax
trap was subsequently desorbed to the GC-MS in splitless mode by a
TD-100 autosampler (Markes International, Llantrisant, UK). The
compounds were separated on a DB-FFAP GC column (60 m.times.0.250
mm.times.25 um) using following temperature gradient: 30.degree. C.
for 10 min; increase at 4.degree. C./min until 50.degree. C.;
increase at 10.degree. C./min until 245.degree. C. and hold until
35 min. The components were detected by a 5975C single quad mass
spectrometer (Agilent Technologies, Morges, Switzerland) operating
in SIM mode. Data were analysed using the MassHunter Quant software
(Version B.05.02, Agilent Technologies). Again, a representative
group of key coffee odorants (thiols, sulfides, Strecker aldehydes,
diketones, pyrazines and phenols) was measured. Samples which were
produced according to a process of the present invention were
compared to the corresponding reference sample. Every sample was
extracted and measured at least four times.
[0368] Results
[0369] The table below gives an overview of the differences
measured in-cup and around the machine in terms of the key coffee
odorants. For every blend, a comparison was made with the
corresponding reference product, which was considered as 100%.
TABLE-US-00003 comparison (%) relatively to untreated product
(considered as 100%) in-cup error (%) around machine error (%)
Arpeggio 130 2 169 11 Ristretto 134 5 135 16 Indryia 121 6 n/a Roma
124 5 n/a Fortissio 123 9 n/a Other blend 130 2 n/a
Example 3
[0370] In a further experiment, the capsules were evaluated by
determining sensory profiles.
[0371] Experimental Setup
[0372] Comparative profiles were obtained from 12 assessors using a
simplified cupping procedure determining crema, aroma, flavour, and
texture. The procedure was repeated once. Nespresso Concept
(trademark) machines filled with Nestle Aqua Panna water were used
to test the capsules according to the invention as well as
reference capsules at 40 ml of dosage.
[0373] Sensory Profiles
[0374] The objective was to evaluate the sensory impact of the
coffee prepared from capsules obtained according to a process of
the present invention. The coffee beans were roasted coffee,
tempered and pre-cooled at -20.degree. C. and then ground,
normalized and degased during 5 min at 5.degree. C. The roast and
ground coffee was then directly filled into the capsule at the
corresponding weight depending of the blend. The capsules were
evaluated against capsules containing coffee processed according to
a standard process (reference). In the standard process, coffee
beans were roasted, tempered, ground, normalized, then degased
during 30 min at 30.degree. C. and then directly filled into the
capsule at the corresponding weight depending of the blend. A lot
of attributes were found to be significantly improved in the
intense coffee blends prepared according to the invention:
Arpeggio (a coffee blend identical to the one contained in the
commercial Arpeggio capsule) from a capsule produced according to
the present invention (batch 222173) was perceived more intense and
roasty in flavour, more bitter/persistent than the reference (batch
216205) as well as with more body. The crema was found darker and
with more quantity. See also FIG. 4. Bars with spaced hatching
signify the presence of a significant difference for a given
attribute, confidence interval 95%. Roma (a coffee blend identical
to the one contained in the commercial Roma capsule) from a capsule
produced according to the present invention (batch 228195) was
found more intense/roasty/cereal in overall aroma and flavour as
well as more persistent than the reference (batch 228193). See also
FIG. 5. Bars with spaced hatching signify the presence of a
significant difference for a given attribute, confidence interval
95%. Ristretto (a coffee blend identical to the one contained in
the commercial Ristretto capsule) from a capsule produced according
to the present invention (batch 227025) was darker, more intense in
overall aroma/flavour, more roasty (aroma/flavour), less fruity
(flavour), more robusta, more bitter, less smooth with more body
and more persistent that the reference (batch 222569). See also
FIG. 6. Bars with spaced hatching signify the presence of a
significant difference for a given attribute, confidence interval
95%.
Example 4
[0375] It was demonstrated that the aroma retention increases with
a decrease of the processing temperature. Cold processing with
pre-cooled roasted coffee enhances aroma recovery. Consumer
preference was also demonstrated by preference test: win on
Arpeggio with similar net weight and parity on Fortissio with
reduced net weight.
[0376] However, due to the reduced degassing time and temperature
during cold processing, higher retention of CO.sub.2 results in a
higher internal pressure in the filled and sealed capsule. Together
with the aroma retention, the carbon dioxide release from the
coffee is reduced, which leads to higher capsule internal pressure.
Consequently, this higher internal capsule pressure was raised as a
major technical constraint when using cold processing with
pre-cooled roasted coffee.
[0377] Preliminary results from mechanistic model have demonstrated
that increased initial rim angle should help the membrane to resist
to higher pressures. Consequently, the objective was to demonstrate
the impact of higher rim angle at laboratory scale on capsule
resistance in order to see potential benefit for capsules with
over-pressure as well as the impact of thicker membrane
[0378] The objective was to modulate the capsule internal pressure
from 300 mbar to 500 mbar with higher rim angle (12 to 28 degrees).
Trials with the standard membrane (30 .mu.m) were performed on
Arpeggio blend under different degassing and temperature conditions
with cold processing, as shown in FIG. 2.
[0379] From 12.degree. to 16.degree. rim angles, capsules were bent
directly on the pilot plant. Other capsules with rim angles
superior to 16.degree. at time zero were bent manually.
[0380] Process parameters are summarized in the table below.
TABLE-US-00004 Cooling water T.degree. C. Roasted Grinder/ Beans
Normalizer/ Membrane Internal temp. Degassing Degassing Thickness
Rim Angle Pressure Trials (.degree. C. ) unit time (min) (.mu.m)
(degree) (mbar after 7 days) Arpeggio Ref -20
5.degree./5.degree./30.degree. C. 5/20/35 30
12.degree./16.degree./19.degree. 300/400/500 1 21.degree./28 Ref
-20 5.degree./5.degree./5.degree. C. 5/20/35
12.degree./16.degree./19.degree. 300/400/500 2
21.degree./28.degree. Ristretto Ref. 3 Industrial trial conditions
40 12.degree. 400/500
[0381] Capsules were analyzed for internal pressure. Capsule
internal pressure was measured by placing the capsule in a
pressurized chamber (as described earlier) 7 days after
filling.
[0382] Rim angles were measured at time zero and 3 times over 8
weeks with a laser instrument.
[0383] The instrument is a laser which can measure the angle
between the two points as described in the present patent
application.
[0384] The rim angle was defined by the level between two points
placed on the flat part of the rim. These two points have to be on
the capsule diameter. Membrane protection just after the sealing
process and delamination are the two arguments which play a role
for the rim angle determination. Based on these two arguments, it
was demonstrated that the recommended folding angle was around
12.+-.2.degree. in order to avoid the membrane damage and limit
delamination (for capsules showing high internal pressure).
[0385] Capsule resistance was tested visually on the membrane.
[0386] Delamination Test: Storage test consists of the delamination
evaluation (visual capsule resistance) of the Arpeggio or Ristretto
capsules produced under different conditions of cold processing
(rim angles & capsule internal pressure; see trials description
above). All capsules are kept in temperature and humidity
controlled chambers at 30.degree. C. and 70% Rh (relative
humidity). The capsules resistance was evaluated every week over 3
months which mimic one year shelf life at room temperatures.
[0387] Capsule resistance was found to increase with higher rim
angle. At 500 mbars of capsule internal pressure, no delamination
was observed over the 3 months at 30.degree. C. with rim angle
>20.degree.. Capsule resistance at intermediate internal
pressure (400 mbar) was visually ok from rim angles >16.degree..
Delamination of the membrane was only observed from 12.degree. to
16.degree. on one capsule after 6 weeks at 30.degree. C. with
standard membrane (30 .mu.m) and no delamination noted with the
thicker membrane (40 .mu.m). Rim angles noted correspond to
measurements performed at time zero.
[0388] Exemplary results for 30 .mu.m and 40 .mu.m membranes are
shown in FIGS. 7 and 8, respectively. FIG. 7 shows capsule
resistance over 3 months at 30.degree. C./70% Rh (internal pressure
from 300 to 500 mbars and rim angles from 12.degree. to 28.degree.
with a standard membrane 30 .mu.m). FIG. 8 shows capsule resistance
over 3 months at 30.degree. C./70% Rh (internal pressure from 400
to 500 mbars and rim angles from 7.degree. to 28.degree. with a
thicker membrane 40 .mu.m)
[0389] To summarize, capsule over-pressure (up to 500 mbar) can be
managed with higher rim angle.
* * * * *