WO2024005773A1 - Compostable barrier lids and beverage capsules - Google Patents

Compostable barrier lids and beverage capsules Download PDF

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Publication number
WO2024005773A1
WO2024005773A1 PCT/US2022/035061 US2022035061W WO2024005773A1 WO 2024005773 A1 WO2024005773 A1 WO 2024005773A1 US 2022035061 W US2022035061 W US 2022035061W WO 2024005773 A1 WO2024005773 A1 WO 2024005773A1
Authority
WO
WIPO (PCT)
Prior art keywords
beverage capsule
lidding
cellulose
lidding structure
paper
Prior art date
Application number
PCT/US2022/035061
Other languages
French (fr)
Inventor
Bruno RUPPANNER
Joana RICHHEIMER
Original Assignee
Amcor Flexibles North America, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Amcor Flexibles North America, Inc. filed Critical Amcor Flexibles North America, Inc.
Priority to PCT/US2022/035061 priority Critical patent/WO2024005773A1/en
Publication of WO2024005773A1 publication Critical patent/WO2024005773A1/en

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Classifications

    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/10Packing paper
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30Multi-ply
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30Multi-ply
    • D21H27/32Multi-ply with materials applied between the sheets
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30Multi-ply
    • D21H27/32Multi-ply with materials applied between the sheets
    • D21H27/34Continuous materials, e.g. filaments, sheets, nets
    • D21H27/36Films made from synthetic macromolecular compounds
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30Multi-ply
    • D21H27/38Multi-ply at least one of the sheets having a fibrous composition differing from that of other sheets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D85/00Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/70Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for
    • B65D85/804Disposable containers or packages with contents which are mixed, infused or dissolved in situ, i.e. without having been previously removed from the package
    • B65D85/8043Packages adapted to allow liquid to pass through the contents
    • B65D85/8061Filters

Definitions

  • This disclosure is related to compostable lidding structures suitable for beverage capsule packaging applications.
  • the lidding structures and beverage capsules disclosed are appropriate for applications in which the beverage is extracted through the lid of the capsule.
  • the beverage preparation product is typically a dry particulate containing either soluble components or a brewable component (i.e., ground coffee beans) or both.
  • the dry product is packaged and distributed for use in a specially designed capsule.
  • the capsule is designed to 1 ) protect the product through distribution and 2) work with a specific beverage preparation machine for brewing.
  • the capsule is punctured and the product is exposed to hot water.
  • the now transformed water i.e., the beverage
  • the capsule is typically a highly engineered product, meeting many stringent requirements of performance.
  • the capsule must hermetically seal to protect the dry product through distribution.
  • the capsule requires special characteristics in order to properly interact with the beverage preparation machine during the beverage preparation process. These characteristics may include, but are not limited to, appropriate puncture strength in one or more areas of the capsule, resistance to deformation under high temperatures, resistance to tears and bursting under pressure, maintenance of seals at high temperature, humidity and pressure, and filtration.
  • the spent capsule Upon completion of the beverage preparation cycle, the spent capsule is removed from the machine and is ready for disposal.
  • the capsule design and assembly often prevent recycling of the unit, due to a mix of capsule material types and the presence of contaminating food product (i.e., remaining coffee grounds).
  • a preferred end-of-life scenario for the spent capsule includes biodegradation or composting.
  • lidding structure with a configuration and design that facilitates the use of compostable materials for the lid and the entire capsule while meeting the necessary requirements put thereon for the distribution of the beverage capsules, the preparation of beverages and disposal by composting.
  • Embodiments of the lidding structure disclosed herein include a cellulose-based paper located at a first surface of the lidding structure, a filter paper located at a second surface of the lidding structure, and an adhesive layer located between the cellulose-based paper and the filter paper.
  • the adhesive layer has a basis weight in a range of from 1 g/m 2 to 8 g/m 2 and the lidding structure has a total composition including a cellulose content in a range of from 80 % to 99 %, by weight.
  • the filter paper may be non-sealable to itself.
  • the filter paper may comprise, consist essentially of, or consist of cellulose fibers.
  • the filter paper may have a basis weight in a range of from 10 g/m 2 to 40 g/m 2 .
  • the filter paper may have a Bendtsen roughness of less than 4000 mL/min, measured according to ISO 8791-2.
  • the cellulose-based paper may have an oxygen transmission rate in a range of from 0.5 mL/m 2 /day to 2 mL/m 2 /day, according to ASTM F1927.
  • the cellulose-based paper may be a microfibrillated cellulose (MFC) paper.
  • the cellulose-based paper may have a basis weight in a range of from 40 g/m 2 to 90 g/m 2 .
  • the adhesive layer may comprise a thermoplastic-based adhesive.
  • the thermoplastic-based adhesive may comprise one or more of acrylic based polymers, vinyl acetate copolymers and ethylene waxes.
  • the adhesive may have a moisture vapor transmission rate in a range of from 5 g/m 2 d to 50 g/m 2 d according to ASTM F1249.
  • Some embodiments of the lidding structure may have a total composition including a cellulose content between 90 % and 99 %, by weight. Some embodiments of the lidding structure have a total composition including a renewable raw material content in a range of from 80 % to 99 %, by weight.
  • the adhesive layer may be directly connected to the cellulose-based paper and the adhesive layer may be directly connected to the filter paper. Additionally, the cellulose-based paper, the filter paper and the adhesive layer may be coextensive with each other.
  • Embodiments of a beverage capsule disclosed herein include a lidding structure and a container including a compostable polymer.
  • the compostable polymer may be one or more of PLA, PHA, or PBS.
  • the filter paper of the lidding structure is hermetically sealed to the compostable polymer of the container.
  • the beverage capsule may be compostable according to standard EN 13432.
  • Some embodiments of a beverage capsule include a dry beverage mix located between the container and the lidding structure.
  • the compostable polymer of the container may be located within the pores of the filter paper.
  • Figure 1 is a perspective view of an embodiment of a beverage capsule including a lidding structure and a container;
  • Figure 2 is a cross-sectional view of an embodiment of a beverage capsule.
  • Figure 3 is a cross-sectional view of an embodiment of a lidding structure.
  • thermoplastic fiber content such as PLA fiber.
  • PLA fiber a material that promotes attachment of the lidding structure to the beverage capsule container by way of heat sealing.
  • these solutions have resulted in beverage capsules with poor brewing performance, typically encountering uncontrolled behavior during beverage extraction.
  • the lidding structure embodiments and beverage capsule embodiments described herein overcome these shortcomings, providing a fully functional beverage capsule capable of high performance for distribution (i.e., hermeticity and barrier) and beverage preparation (i.e., controlled and consistent extraction), in combination with compostability.
  • the lidding structure solutions provided here include two layers of cellulose type materials connected by an adhesive layer.
  • the adhesive layer may include a thermoplastic-based adhesive.
  • the filter paper surface of the lidding structure containing 100 % cellulose-based material, is hermetically sealed to the capsule container. It was surprisingly found that a lidding structure having an exposed filter paper surface which is free from a thermoplastic material and is appropriate for filtering the beverage product during brewing, can form a suitable hermetic seal to the capsule container.
  • this type of filter paper also performs consistently well during the extraction process of the brewing cycle.
  • the current lidding structure includes a filter paper located at the interior facing surface and such that the filter paper is in direct contact with the product inside the beverage capsule. This configuration leads to faster and easier beverage extraction due to the exposure of the water/product mixture to the full interior surface, the entire interior surface capable of contributing to the filtration. There is no thermoplastic material between the filter medium (i.e., the filter paper) and the brewing product.
  • a compostable lidding structure including a cellulose filter paper as described herein at the sealing surface, could be hermetically heat sealed to a compostable container providing suitable pressure resistance and hermiticity.
  • the beverage capsules 100 disclosed herein generally include a rigid or semi-rigid container 20, a lidding structure 10 and a product 30.
  • the beverage capsules may also include other components such as filters, labels or sleeves.
  • Figure 1 shows a perspective view of an embodiment of a beverage capsule 100 having a cylindrical symmetry, the container 20 being cup shaped and the lidding structure 10 being disk shaped.
  • a cross-sectional view of the embodiment of the beverage capsule 100 is shown in Figure 2, now showing the product 30 located between the container 20 and the lidding structure 10.
  • the container 20 is shown having a flange 22 (i.e., a flat lip area) with a sealing surface 24 to which the interior facing surface (or second surface) 14 of the lidding structure 10 is attached.
  • the product 30 is in contact with the container 20 and the interior facing surface 14 of the lidding structure 10.
  • the exterior facing surface (or first surface) 12 of the lidding structure 10 is exposed to the environment surrounding the beverage capsule 100.
  • the container of the beverage capsule may be made from a compostable polymer such as polylactic acid (PLA), polyhydroxybutyrate (PHA) or polybutylene succinate (PBS).
  • the container may comprise of one or more compostable polymers or the container may comprise a single compostable polymer.
  • the container may comprise PLA.
  • the container may consist of one or more compostable polymers or the container may consist of a single compostable polymer.
  • the container may consist of PLA.
  • the container may have a composition considered to be fully compostable according to standard EN 13432.
  • the container may be monolayer or multilayer.
  • the lidding container will have a surface upon which the lidding can be attached by sealing.
  • the open mouth of the container may include a flat flange and/or a rolled edge around the perimeter.
  • the surface upon which the lidding is sealed to i.e. , the sealing surface of the container
  • the surface of the container upon which the lidding is sealed is made from PLA.
  • the compostable polymer of the container softens and flows into the pores found in the filter paper at the interior facing surface (i.e., the second surface) of the lidding structure. After sealing, the compostable polymer that has flowed into the filter paper pores solidifies, providing a solid physical adhesion mechanism resulting in a very high burst strength. It was surprisingly found that sealing of the lidding structure to the container in this manner provides for a hermetically sealed package.
  • “hermetically sealed package” or “hermetically sealed” refers to a sealed package or seal that is completely closed and essentially airtight. Hermetically sealed packages generally have a need for storage and package integrity over a period of time that is greater than a few days. Hermetically sealed packages may offer the benefit of maintaining the integrity of a product at high quality for many months.
  • the container may have physical properties that allow for proper brewing. For example, the container may need to be punctured, without cracking. The container should not deform at the temperatures at which the brewing process occurs.
  • the beverage capsule contains dry beverage mix.
  • dry beverage mix includes a dry particulate product from which a beverage can be produced. Examples of products that may be considered a dry beverage mix includes but is not limited to soluble particulates (i.e., flavorings, creamer), ground coffee beans and dried tea components. The maintenance of the dry nature of the product may be critical to the proper beverage preparation or prepared beverage quality.
  • the beverage capsule, including the container and the lidding structure independently, may have a very low moisture vapor transmission rate to protect the product from moisture during storage and distribution of the beverage capsule.
  • the beverage capsule contains ground coffee.
  • the ground coffee may be in an amount to brew a single portion of a coffee beverage.
  • a volume of hot water of between 30 mL (espresso beverage) to 300 mL (standard drip coffee) is injected into the beverage capsule and extracted therefrom, using a percolation process that may last up to about one minute.
  • the beverage capsules may be stored and distributed prior to use in single serve beverage machines (i.e., a brewing device).
  • the beverage capsules are designed for use in a single serve coffee or espresso machine.
  • the bottom of the capsule i.e., the container
  • heated water is pumped into the cavity of the capsule.
  • Pressure builds within the capsule and the lid is then partially perforated, allowing the brewed beverage to flow out of the capsule, through the filter of the lidding structure and into a cup.
  • the capsule is then ejected from the machine.
  • the lidding material must maintain a seal against the container and not split or burst.
  • the lidding structure must maintain integrity.
  • the lidding structure does not split or tear when it is subjected to pressure of between 5 and 15 bars.
  • the lid Before the lidding structure is perforated, the lid must not tear under the rising pressure of the water in the capsule.
  • the lidding structure is partially perforated with small holes during brewing. After the lidding structure is perforated, the holes from the perforation must maintain their shape and the lidding structure does not allow large tears to propagate from the perforation holes.
  • the lidding structure must perforate properly, allowing the beverage to pass out of the beverage capsule.
  • the lidding structure must not tear further from the perforation points, thus maintaining filtering capabilities and retaining the coffee grounds or other undissolved particulates from passing out of the beverage capsule.
  • the beverage capsule may have a composition that qualifies as compostable according to standard EN 13432.
  • Each of the components of the beverage capsule, including the container, the lidding structure and the product may each independently be compostable according to standard EN 13432.
  • the beverage capsule may have a composition that qualifies as home compostable according to Australian standard AS 5810 or French standard NF T 51800. This is particularly advantageous as the capsule configuration is difficult to recycle or reuse.
  • each of the components of the beverage capsule, including the container, the lidding structure and the product may each independently comprise at least 80 % renewable raw material content, by weight.
  • the product may be a ground coffee and the container may be made of PLA, each of which are renewable raw materials.
  • the lidding structure may contain at least 80 % renewable raw material content (i.e. , cellulose-based material), by weight.
  • the beverage capsule, including the container, the lidding structure and the product may each independently comprise at least 80 %, at least 85 %, at least 90 % or at least 95 % renewable raw material content, by weight.
  • an advantageous lidding structure 10 This design includes a layer including a cellulose-based paper 16, a layer including a filter paper 18 and a layer including an adhesive 17.
  • Some embodiments of the lidding structure may consist of a cellulose based paper, a filter paper and a thermoplastic-based adhesive.
  • the adhesive layer 17 is located between the cellulose-based paper 16 and the filter paper 18.
  • the adhesive layer 17 is in direct contact with each of the cellulose-based paper 16 and the filter paper 18, adhering these components to each other.
  • the embodiment of the lidding structure 10 shown in Figure 3 includes the cellulose-based paper 16 located at a first surface 12 of the lidding structure 10 and the filter paper 18 located at a second surface 14 of the lidding structure 10.
  • the first surface 12 is also an exterior facing surface, exposed to the environment
  • the second surface 14 is also an interior facing surface, exposed to the product within the package (see Figure 2).
  • a layer refers to a building block of a structure, film or laminate that is composed of a single material type or a homogeneous blend of materials.
  • a layer may be a single material type, a blend of materials within a single material type or a blend of various materials. Layers may be continuous with the structure (i.e., coextensive with the structure) or may be discontinuous or patterned.
  • a layer generally has an insignificant thickness (z direction) as compared to the length and width (x-y direction), and therefore is defined to have two surfaces, the area of which are defined by the length and width of the layer.
  • An outer layer is one that is connected to another layer at only one of the layer surfaces. In other words, one surface of an outer layer is exposed.
  • An inner layer is one that is connected to another layer at both surfaces. In other words, an inner layer is between two other layers.
  • a layer may have sub-layers.
  • the term “exterior facing layer” or “exterior facing surface” is used to describe an outer layer or surface that is located on one of the surfaces of the structure in which it is comprised and is exposed to the outside environment when it is incorporated into a package such as a beverage capsule.
  • the term “interior facing layer” or “interior facing surface” is used to describe an outer layer or surface that is exposed to the packaged product (i.e., a dry beverage mix) or the inside environment of a package.
  • the term "adhesive layer” refers to a layer or material placed on one or more layers to promote the adhesion of that layer to another surface. Adhesive layers may be positioned between two layers of a laminate to maintain the two layers in position relative to each other and prevent undesirable delamination.
  • the lidding structure may take various formats. As applied to a beverage capsule, and as shown in Figures 1 and 2, the lidding structure may be cut to a disk shape.
  • the lidding structure as applied to a beverage capsule may take other shapes (i.e., hexagonal, square) that may generally conform to the shape of the container it is sealed to.
  • the lidding structure may have a similar disk (or other shape) format prior to being attached to a container.
  • the lidding structure is preferably produced by wide roll-to-roll manufacturing processes, as is known in the packaging industry.
  • the lidding structure may be in a “web” format, wrapped on a roll or cut into sheets.
  • the cellulose-based paper that is located on the first surface of the lidding structure may have a basis weight in a range of from 40 g/m 2 to 90 g/m 2 , or from 40 g/m 2 to 80 g/m 2 , or from 50 g/m 2 to 75 g/m 2 .
  • the term “cellulose-based paper” refers to a paper web containing cellulose as the main component.
  • the cellulose-based paper may contain fibers that are 100 % cellulose.
  • the cellulose-based paper is renewably resourced, compostable and biodegradable.
  • inks and/or other coatings located on the exterior facing surface of the cellulose-based paper, providing graphics for the beverage capsule.
  • the inks and/or coatings are compostable according to EN 13432.
  • Basis weight is used to refer to the amount of material by weight is present in a predetermined area of a film or layer. Typically, the area defined is a square meter, but any area can be used. The area is defined in the length-width (i.e., x-y direction) of the film or layer. A material of a given thickness (z-direction) and density, has a specific weight when covering a defined area (i.e., a square meter). Basis weight is a commonly used measurement of weight for paper because the density of paper can vary widely. Stated differently, measuring paper by thickness can be difficult and as a result, basis weight is used.
  • materials that are applied in discontinuous layers can be defined by basis weight.
  • the basis weight refers to the amount of material by weight that is present when covering a defined area. The use of basis weight to measure weight of materials such as paper and patterned materials is common in the film converting industry.
  • the cellulose-based paper should have good wet strength. Typical values for good wet strength are ⁇ 30 g/m 2 . Similarly, the cellulose-based paper should not swell upon exposure to moisture. Water absorption for paper is measured with the Tappi norm T441 (Cobb 60). The oxygen transmission rate (OTR) of the cellulose- based paper may be less than 2 mL/m 2 /day according to ASTM F1927.
  • the cellulose-based paper may be a microfibrillated cellulose (MFC) paper.
  • MFC microfibrillated cellulose
  • Microfibrillated cellulose is a material composed of nano-sized cellulose fibrils with a high length to width ratio. Typical lateral dimensions are 5 to 20 nm and longitudinal dimension may range from less than one nanometer to several microns.
  • Microfibrillated cellulose is obtained by special treatment of any cellulose containing source including wood-based fibers. Paper that contains microfibrillated cellulose is commercially available and its properties are as such known.
  • the filter paper that is located on the second surface of the lidding structure may have a basis weight in a range of from 10 g/m 2 to 40 g/m 2 , or from 10 g/m 2 to 35 g/m 2 .
  • filter paper has the common meaning of a paper that is porous, unsized and unglazed. Filter paper may be bleached or unbleached. Filter paper is permeable to water or extracted beverage liquid but does not allow large solid particles to pass. The majority of ground coffee particles or other particles will be stopped by the filter paper and will not be extracted with the beverage liquid.
  • the filter paper may have a Bendtsen roughness of less than 4000 mL/min.
  • the roughness of the filter paper can be measured according to ISO 8791 -2.
  • the smoothness of the filter paper contributes to its ability to form a good (i.e., hermetic) seal with the container.
  • the filter paper used for the flexible lidding structure may be cellulose- based.
  • the filter paper may comprise fibers that are 100 % cellulose.
  • the filter paper used for the flexible lidding structure is free from thermoplastic fibers, such as PLA fibers.
  • the filter paper is renewably resourced, compostable and biodegradable.
  • the filter paper may be non-sealable to itself, which means that no bond is achieved if the filter paper is heat sealed against itself. This non-sealability to itself is a function of the high cellulose content since the cellulose material does not soften at elevated temperatures. Without the presence of thermoplastic fibers, the filter paper does not soften at elevated temperatures and does not form a heat seal to itself under normal heat sealing conditions. Filter paper should offer taste neutrality and should comply with food contact regulations.
  • Comparative lidding structures were produced using 1 ) a filter paper that contained fibers made of PLA and 2) a non-woven PLA to replace the cellulose-based filter paper of this disclosure. These types of structures would be compostable and heat sealed well to a PLA container. However, the inventors found that these comparative structures had poor performance during the extraction process (i.e., displayed uncontrolled behavior). Upon replacing this layer with a cellulose-based filter paper according to this disclosure, the sealing performance surprisingly remained good and the extraction was greatly improved in the beverage capsule applications. Despite the fact of a lack of thermoplastic material at the interior facing surface (i.e., the filter paper located at the second surface) of the lidding structures described herein, a suitable hermetic seal was achieved.
  • the adhesive layer that is located between the cellulose-based paper and the filter paper may have a basis weight in a range of from 1 g/m 2 to 8 g/m 2 .
  • the lower level of this range provides for enough material to sufficiently bond the paper layers.
  • the upper level of this range provides for the maximum benefits of the adhesive (i.e., bond strength, moisture barrier) without hindering the extraction process during brewing. If more adhesive is added, the lidding structure may not perforate correctly, the lidding structure may tend to tear during extraction or the beverage may not extract at an appropriate speed.
  • the material used in the adhesive layer may include but is not limited to a thermoplastic based material such as an acrylic based polymer, a vinyl acetate copolymer or and ethylene wax.
  • the adhesive layer may include one or more sub-layers. In some embodiments of the lidding structure, the adhesive layer is directly connected to the cellulose-based paper and the thermoplastic-based adhesive layer.
  • the adhesive should have a melting point above 100°C to avoid any delamination or dissolving during the brewing process.
  • the lidding structure should provide suitable moisture barrier.
  • the adhesive layer may have a moisture vapor transmission rate in a range of from 5 g/m 2 d to 50 g/m 2 d according to ASTM F1249.
  • the lidding structure may have a total composition that includes a cellulose content in a range of from 80 % to 99 %, or from 90 % to 99 %, by weight.
  • the lidding structure may have a total composition that includes a cellulose content of at least 80 % or at least 90 %, by weight.
  • the lidding structure should have a total composition that includes a renewable material content in a range of from 80 % to 99 %, or from 90 % to 99 %, by weight.
  • the lidding structure may have an oxygen transmission rate of in a range of from 0.5 mL/m 2 /day to 2 mL/m 2 /day, according to ASTM F1927.
  • Sample A included a lamination of a barrier paper and a PLA non-woven material.
  • Sample B included a lamination of a barrier paper and a sealable filter paper having PLA fibers.
  • Sample C included a lamination of a barrier paper and an all cellulose based filter paper.
  • An acceptable extraction time for this type of extraction process is between 20 and 40 seconds, which each of the samples met.
  • Sample C including the cellulose based filter paper, demonstrated the fastest extraction time.
  • the water wasted is the amount of water used in the process that was not part of the extracted beverage quantity.
  • the extracted quantity should be as close as possible to the target 100 mL.
  • Sample A has a markedly higher waste volume and a correspondingly low extracted quantity. This is indicative of a high extraction pressure and an uncontrolled flow during extraction.
  • Sample B has a much better (lower) waste value, but still demonstrates a rather low extracted quantity.
  • Sample C using the cellulose based filter paper, has a high extracted quantity of 86 mL, which is close to non-compostable brewing capsules used today, which have an extracted quantity of just over 90 mL in this extraction test.

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Abstract

Provided herein is a compostable beverage capsule including a compostable lidding structure and a container. The lidding structure comprises a cellulose- based paper on the exterior facing surface, a filter paper on the interior facing surface and an adhesive between the cellulose-based paper and the filter paper. A thermoplastic-based adhesive layer may provide moisture barrier and the lidding structure has an overall cellulose content or renewable raw material content between 80 % and 99 %, by weight.

Description

COMPOSTABLE BARRIER LIDS AND BEVERAGE CAPSULES
TECHNICAL FIELD
[001] This disclosure is related to compostable lidding structures suitable for beverage capsule packaging applications. The lidding structures and beverage capsules disclosed are appropriate for applications in which the beverage is extracted through the lid of the capsule.
BACKGROUND
[002] Single-serve beverage preparation has become common-place for hot drinks such as coffee or tea. The beverage preparation product is typically a dry particulate containing either soluble components or a brewable component (i.e., ground coffee beans) or both. The dry product is packaged and distributed for use in a specially designed capsule. The capsule is designed to 1 ) protect the product through distribution and 2) work with a specific beverage preparation machine for brewing. During beverage preparation the capsule is punctured and the product is exposed to hot water. The now transformed water (i.e., the beverage) is then extracted from the capsule and dispensed.
[003] The capsule is typically a highly engineered product, meeting many stringent requirements of performance. The capsule must hermetically seal to protect the dry product through distribution. The capsule requires special characteristics in order to properly interact with the beverage preparation machine during the beverage preparation process. These characteristics may include, but are not limited to, appropriate puncture strength in one or more areas of the capsule, resistance to deformation under high temperatures, resistance to tears and bursting under pressure, maintenance of seals at high temperature, humidity and pressure, and filtration.
[004] Upon completion of the beverage preparation cycle, the spent capsule is removed from the machine and is ready for disposal. The capsule design and assembly often prevent recycling of the unit, due to a mix of capsule material types and the presence of contaminating food product (i.e., remaining coffee grounds). A preferred end-of-life scenario for the spent capsule includes biodegradation or composting.
[005] Designing beverage capsules that are suitable for biodegradation or composting remains a challenge. Often, the materials compatible with these end-of-life processes are not suitable for packaging because they do not hold up to the rigorous performance demands of the capsules. Compostable polymeric materials such as PLA, PHA, and starch-based polymers typically do not have the physical properties necessary to deliver the needed barrier and/or mechanical performance.
SUMMARY
[006] It is an object of the present disclosure to overcome the shortcomings of the previous designs of compostable lidding structures and beverage capsules. Provided herein is a lidding structure with a configuration and design that facilitates the use of compostable materials for the lid and the entire capsule while meeting the necessary requirements put thereon for the distribution of the beverage capsules, the preparation of beverages and disposal by composting. These and other objects, which become apparent upon reading the description, are provided by the features of the independent claims. The dependent claims refer to specific embodiments of the lidding structure and beverage capsule.
[007] Embodiments of the lidding structure disclosed herein include a cellulose-based paper located at a first surface of the lidding structure, a filter paper located at a second surface of the lidding structure, and an adhesive layer located between the cellulose-based paper and the filter paper. The adhesive layer has a basis weight in a range of from 1 g/m2 to 8 g/m2 and the lidding structure has a total composition including a cellulose content in a range of from 80 % to 99 %, by weight.
[008] The filter paper may be non-sealable to itself. The filter paper may comprise, consist essentially of, or consist of cellulose fibers. The filter paper may have a basis weight in a range of from 10 g/m2 to 40 g/m2. The filter paper may have a Bendtsen roughness of less than 4000 mL/min, measured according to ISO 8791-2. [009] The cellulose-based paper may have an oxygen transmission rate in a range of from 0.5 mL/m2/day to 2 mL/m2/day, according to ASTM F1927. The cellulose-based paper may be a microfibrillated cellulose (MFC) paper. The cellulose-based paper may have a basis weight in a range of from 40 g/m2 to 90 g/m2.
[010] The adhesive layer may comprise a thermoplastic-based adhesive. The thermoplastic-based adhesive may comprise one or more of acrylic based polymers, vinyl acetate copolymers and ethylene waxes. The adhesive may have a moisture vapor transmission rate in a range of from 5 g/m2d to 50 g/m2d according to ASTM F1249.
[011] Some embodiments of the lidding structure may have a total composition including a cellulose content between 90 % and 99 %, by weight. Some embodiments of the lidding structure have a total composition including a renewable raw material content in a range of from 80 % to 99 %, by weight.
[012] Some embodiments of the lidding structure, such as the embodiment shown in Figure 3 herein, the adhesive layer may be directly connected to the cellulose-based paper and the adhesive layer may be directly connected to the filter paper. Additionally, the cellulose-based paper, the filter paper and the adhesive layer may be coextensive with each other.
[013] Embodiments of a beverage capsule disclosed herein include a lidding structure and a container including a compostable polymer. The compostable polymer may be one or more of PLA, PHA, or PBS. The filter paper of the lidding structure is hermetically sealed to the compostable polymer of the container. The beverage capsule may be compostable according to standard EN 13432.
[014] Some embodiments of a beverage capsule include a dry beverage mix located between the container and the lidding structure.
[015] The compostable polymer of the container may be located within the pores of the filter paper.
BRIEF DESCRIPTION OF THE DRAWINGS [016] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:
[017] Figure 1 is a perspective view of an embodiment of a beverage capsule including a lidding structure and a container;
[018] Figure 2 is a cross-sectional view of an embodiment of a beverage capsule; and
[019] Figure 3 is a cross-sectional view of an embodiment of a lidding structure.
[020] The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings.
DETAILED DESCRIPTION
[021] Previous solutions of compostable lidding structures to be used on beverage capsules have included thermoplastic fiber content, such as PLA fiber. The presence of this material promotes attachment of the lidding structure to the beverage capsule container by way of heat sealing. However, these solutions have resulted in beverage capsules with poor brewing performance, typically encountering uncontrolled behavior during beverage extraction. The lidding structure embodiments and beverage capsule embodiments described herein overcome these shortcomings, providing a fully functional beverage capsule capable of high performance for distribution (i.e., hermeticity and barrier) and beverage preparation (i.e., controlled and consistent extraction), in combination with compostability.
[022] The lidding structure solutions provided here include two layers of cellulose type materials connected by an adhesive layer. The adhesive layer may include a thermoplastic-based adhesive. The filter paper surface of the lidding structure, containing 100 % cellulose-based material, is hermetically sealed to the capsule container. It was surprisingly found that a lidding structure having an exposed filter paper surface which is free from a thermoplastic material and is appropriate for filtering the beverage product during brewing, can form a suitable hermetic seal to the capsule container. Advantageously, this type of filter paper also performs consistently well during the extraction process of the brewing cycle.
[023] The current lidding structure includes a filter paper located at the interior facing surface and such that the filter paper is in direct contact with the product inside the beverage capsule. This configuration leads to faster and easier beverage extraction due to the exposure of the water/product mixture to the full interior surface, the entire interior surface capable of contributing to the filtration. There is no thermoplastic material between the filter medium (i.e., the filter paper) and the brewing product.
[024] Unexpectedly, the inventors found that a compostable lidding structure, including a cellulose filter paper as described herein at the sealing surface, could be hermetically heat sealed to a compostable container providing suitable pressure resistance and hermiticity.
BEVERAGE CAPSULE
[025] As shown in Figures 1 and 2, the beverage capsules 100 disclosed herein generally include a rigid or semi-rigid container 20, a lidding structure 10 and a product 30. The beverage capsules may also include other components such as filters, labels or sleeves. Figure 1 shows a perspective view of an embodiment of a beverage capsule 100 having a cylindrical symmetry, the container 20 being cup shaped and the lidding structure 10 being disk shaped. A cross-sectional view of the embodiment of the beverage capsule 100 is shown in Figure 2, now showing the product 30 located between the container 20 and the lidding structure 10. The container 20 is shown having a flange 22 (i.e., a flat lip area) with a sealing surface 24 to which the interior facing surface (or second surface) 14 of the lidding structure 10 is attached. The product 30 is in contact with the container 20 and the interior facing surface 14 of the lidding structure 10. The exterior facing surface (or first surface) 12 of the lidding structure 10 is exposed to the environment surrounding the beverage capsule 100.
[026] The container of the beverage capsule may be made from a compostable polymer such as polylactic acid (PLA), polyhydroxybutyrate (PHA) or polybutylene succinate (PBS). The container may comprise of one or more compostable polymers or the container may comprise a single compostable polymer. In some embodiments of the beverage capsule, the container may comprise PLA. The container may consist of one or more compostable polymers or the container may consist of a single compostable polymer. In some embodiments of the beverage capsule, the container may consist of PLA.
[027] The container may have a composition considered to be fully compostable according to standard EN 13432. The container may be monolayer or multilayer. The lidding container will have a surface upon which the lidding can be attached by sealing. For example, the open mouth of the container may include a flat flange and/or a rolled edge around the perimeter. The surface upon which the lidding is sealed to (i.e. , the sealing surface of the container) comprises one or more of the compostable polymers. In some embodiments, the surface of the container upon which the lidding is sealed is made from PLA.
[028] During the process of sealing the lidding structure to the container, the compostable polymer of the container softens and flows into the pores found in the filter paper at the interior facing surface (i.e., the second surface) of the lidding structure. After sealing, the compostable polymer that has flowed into the filter paper pores solidifies, providing a solid physical adhesion mechanism resulting in a very high burst strength. It was surprisingly found that sealing of the lidding structure to the container in this manner provides for a hermetically sealed package. As used herein, “hermetically sealed package” or “hermetically sealed” refers to a sealed package or seal that is completely closed and essentially airtight. Hermetically sealed packages generally have a need for storage and package integrity over a period of time that is greater than a few days. Hermetically sealed packages may offer the benefit of maintaining the integrity of a product at high quality for many months.
[029] Additionally, the container may have physical properties that allow for proper brewing. For example, the container may need to be punctured, without cracking. The container should not deform at the temperatures at which the brewing process occurs.
[030] In some embodiments, the beverage capsule contains dry beverage mix. As used herein, “dry beverage mix” includes a dry particulate product from which a beverage can be produced. Examples of products that may be considered a dry beverage mix includes but is not limited to soluble particulates (i.e., flavorings, creamer), ground coffee beans and dried tea components. The maintenance of the dry nature of the product may be critical to the proper beverage preparation or prepared beverage quality. The beverage capsule, including the container and the lidding structure independently, may have a very low moisture vapor transmission rate to protect the product from moisture during storage and distribution of the beverage capsule.
[031] In some embodiments, the beverage capsule contains ground coffee. The ground coffee may be in an amount to brew a single portion of a coffee beverage. During brewing, a volume of hot water of between 30 mL (espresso beverage) to 300 mL (standard drip coffee) is injected into the beverage capsule and extracted therefrom, using a percolation process that may last up to about one minute.
[032] The beverage capsules may be stored and distributed prior to use in single serve beverage machines (i.e., a brewing device). In some embodiments, the beverage capsules are designed for use in a single serve coffee or espresso machine.
[033] Typically, upon loading the beverage capsule into a brewing device, the bottom of the capsule (i.e., the container) is punctured and heated water is pumped into the cavity of the capsule. Pressure builds within the capsule and the lid is then partially perforated, allowing the brewed beverage to flow out of the capsule, through the filter of the lidding structure and into a cup. After the brewing cycle is completed, the capsule is then ejected from the machine. For proper brewing, the lidding material must maintain a seal against the container and not split or burst.
[034] During brewing, the lidding structure must maintain integrity. The lidding structure does not split or tear when it is subjected to pressure of between 5 and 15 bars. Before the lidding structure is perforated, the lid must not tear under the rising pressure of the water in the capsule. The lidding structure is partially perforated with small holes during brewing. After the lidding structure is perforated, the holes from the perforation must maintain their shape and the lidding structure does not allow large tears to propagate from the perforation holes. The lidding structure must perforate properly, allowing the beverage to pass out of the beverage capsule. The lidding structure must not tear further from the perforation points, thus maintaining filtering capabilities and retaining the coffee grounds or other undissolved particulates from passing out of the beverage capsule.
[035] The beverage capsule may have a composition that qualifies as compostable according to standard EN 13432. Each of the components of the beverage capsule, including the container, the lidding structure and the product, may each independently be compostable according to standard EN 13432. Additionally, the beverage capsule may have a composition that qualifies as home compostable according to Australian standard AS 5810 or French standard NF T 51800. This is particularly advantageous as the capsule configuration is difficult to recycle or reuse. In some embodiments, each of the components of the beverage capsule, including the container, the lidding structure and the product, may each independently comprise at least 80 % renewable raw material content, by weight. For example, the product may be a ground coffee and the container may be made of PLA, each of which are renewable raw materials. In addition, the lidding structure may contain at least 80 % renewable raw material content (i.e. , cellulose-based material), by weight. Overall, the beverage capsule, including the container, the lidding structure and the product, may each independently comprise at least 80 %, at least 85 %, at least 90 % or at least 95 % renewable raw material content, by weight.
LIDDING STRUCTURE
[036] Referring to the cross-sectional view of an embodiment shown in Figure 3, disclosed herein is an advantageous lidding structure 10. This design includes a layer including a cellulose-based paper 16, a layer including a filter paper 18 and a layer including an adhesive 17. Some embodiments of the lidding structure may consist of a cellulose based paper, a filter paper and a thermoplastic-based adhesive. The adhesive layer 17 is located between the cellulose-based paper 16 and the filter paper 18. In some embodiment of the lidding structure 10 the adhesive layer 17 is in direct contact with each of the cellulose-based paper 16 and the filter paper 18, adhering these components to each other. The embodiment of the lidding structure 10 shown in Figure 3 includes the cellulose-based paper 16 located at a first surface 12 of the lidding structure 10 and the filter paper 18 located at a second surface 14 of the lidding structure 10. When the lidding structure is attached to another packaging component to form a beverage capsule, the first surface 12 is also an exterior facing surface, exposed to the environment, and the second surface 14 is also an interior facing surface, exposed to the product within the package (see Figure 2).
[037] The term "layer", as used herein, refers to a building block of a structure, film or laminate that is composed of a single material type or a homogeneous blend of materials. A layer may be a single material type, a blend of materials within a single material type or a blend of various materials. Layers may be continuous with the structure (i.e., coextensive with the structure) or may be discontinuous or patterned. A layer generally has an insignificant thickness (z direction) as compared to the length and width (x-y direction), and therefore is defined to have two surfaces, the area of which are defined by the length and width of the layer. An outer layer is one that is connected to another layer at only one of the layer surfaces. In other words, one surface of an outer layer is exposed. An inner layer is one that is connected to another layer at both surfaces. In other words, an inner layer is between two other layers. A layer may have sub-layers.
[038] As used herein, the term “exterior facing layer” or “exterior facing surface” is used to describe an outer layer or surface that is located on one of the surfaces of the structure in which it is comprised and is exposed to the outside environment when it is incorporated into a package such as a beverage capsule. As used herein, the term “interior facing layer” or “interior facing surface” is used to describe an outer layer or surface that is exposed to the packaged product (i.e., a dry beverage mix) or the inside environment of a package.
[039] The term "adhesive layer" refers to a layer or material placed on one or more layers to promote the adhesion of that layer to another surface. Adhesive layers may be positioned between two layers of a laminate to maintain the two layers in position relative to each other and prevent undesirable delamination. [040] The lidding structure may take various formats. As applied to a beverage capsule, and as shown in Figures 1 and 2, the lidding structure may be cut to a disk shape. The lidding structure as applied to a beverage capsule may take other shapes (i.e., hexagonal, square) that may generally conform to the shape of the container it is sealed to. The lidding structure may have a similar disk (or other shape) format prior to being attached to a container.
[041 ] The lidding structure is preferably produced by wide roll-to-roll manufacturing processes, as is known in the packaging industry. Thus, the lidding structure may be in a “web” format, wrapped on a roll or cut into sheets.
[042] The cellulose-based paper that is located on the first surface of the lidding structure (i.e., the exterior facing surface of the lidding structure when applied to a beverage capsule), may have a basis weight in a range of from 40 g/m2 to 90 g/m2, or from 40 g/m2 to 80 g/m2, or from 50 g/m2 to 75 g/m2. As used herein, the term “cellulose-based paper” refers to a paper web containing cellulose as the main component. The cellulose-based paper may contain fibers that are 100 % cellulose. The cellulose-based paper is renewably resourced, compostable and biodegradable.
[043] There may be inks and/or other coatings located on the exterior facing surface of the cellulose-based paper, providing graphics for the beverage capsule. Preferably, the inks and/or coatings are compostable according to EN 13432.
[044] As used herein, the term “basis weight” is used to refer to the amount of material by weight is present in a predetermined area of a film or layer. Typically, the area defined is a square meter, but any area can be used. The area is defined in the length-width (i.e., x-y direction) of the film or layer. A material of a given thickness (z-direction) and density, has a specific weight when covering a defined area (i.e., a square meter). Basis weight is a commonly used measurement of weight for paper because the density of paper can vary widely. Stated differently, measuring paper by thickness can be difficult and as a result, basis weight is used. Similarly, materials that are applied in discontinuous layers, such as the patterned sealable material, can be defined by basis weight. In the case of patterns, the basis weight refers to the amount of material by weight that is present when covering a defined area. The use of basis weight to measure weight of materials such as paper and patterned materials is common in the film converting industry.
[045] For good performance of the lidding structure, the cellulose-based paper should have good wet strength. Typical values for good wet strength are < 30 g/m2.Similarly, the cellulose-based paper should not swell upon exposure to moisture. Water absorption for paper is measured with the Tappi norm T441 (Cobb 60). The oxygen transmission rate (OTR) of the cellulose- based paper may be less than 2 mL/m2/day according to ASTM F1927.
[046] The cellulose-based paper may be a microfibrillated cellulose (MFC) paper. Microfibrillated cellulose is a material composed of nano-sized cellulose fibrils with a high length to width ratio. Typical lateral dimensions are 5 to 20 nm and longitudinal dimension may range from less than one nanometer to several microns. Microfibrillated cellulose is obtained by special treatment of any cellulose containing source including wood-based fibers. Paper that contains microfibrillated cellulose is commercially available and its properties are as such known.
[047] The filter paper that is located on the second surface of the lidding structure (i.e., the interior facing surface of the lidding structure when applied to a beverage capsule), may have a basis weight in a range of from 10 g/m2 to 40 g/m2, or from 10 g/m2 to 35 g/m2. As used herein, “filter paper” has the common meaning of a paper that is porous, unsized and unglazed. Filter paper may be bleached or unbleached. Filter paper is permeable to water or extracted beverage liquid but does not allow large solid particles to pass. The majority of ground coffee particles or other particles will be stopped by the filter paper and will not be extracted with the beverage liquid.
[048] The filter paper may have a Bendtsen roughness of less than 4000 mL/min. The roughness of the filter paper can be measured according to ISO 8791 -2. The smoothness of the filter paper contributes to its ability to form a good (i.e., hermetic) seal with the container.
[049] The filter paper used for the flexible lidding structure may be cellulose- based. The filter paper may comprise fibers that are 100 % cellulose. The filter paper used for the flexible lidding structure is free from thermoplastic fibers, such as PLA fibers. The filter paper is renewably resourced, compostable and biodegradable. The filter paper may be non-sealable to itself, which means that no bond is achieved if the filter paper is heat sealed against itself. This non-sealability to itself is a function of the high cellulose content since the cellulose material does not soften at elevated temperatures. Without the presence of thermoplastic fibers, the filter paper does not soften at elevated temperatures and does not form a heat seal to itself under normal heat sealing conditions. Filter paper should offer taste neutrality and should comply with food contact regulations.
[050] Comparative lidding structures were produced using 1 ) a filter paper that contained fibers made of PLA and 2) a non-woven PLA to replace the cellulose-based filter paper of this disclosure. These types of structures would be compostable and heat sealed well to a PLA container. However, the inventors found that these comparative structures had poor performance during the extraction process (i.e., displayed uncontrolled behavior). Upon replacing this layer with a cellulose-based filter paper according to this disclosure, the sealing performance surprisingly remained good and the extraction was greatly improved in the beverage capsule applications. Despite the fact of a lack of thermoplastic material at the interior facing surface (i.e., the filter paper located at the second surface) of the lidding structures described herein, a suitable hermetic seal was achieved.
[051] The adhesive layer that is located between the cellulose-based paper and the filter paper may have a basis weight in a range of from 1 g/m2 to 8 g/m2. The lower level of this range provides for enough material to sufficiently bond the paper layers. The upper level of this range provides for the maximum benefits of the adhesive (i.e., bond strength, moisture barrier) without hindering the extraction process during brewing. If more adhesive is added, the lidding structure may not perforate correctly, the lidding structure may tend to tear during extraction or the beverage may not extract at an appropriate speed.
[052] The material used in the adhesive layer may include but is not limited to a thermoplastic based material such as an acrylic based polymer, a vinyl acetate copolymer or and ethylene wax. The adhesive layer may include one or more sub-layers. In some embodiments of the lidding structure, the adhesive layer is directly connected to the cellulose-based paper and the thermoplastic-based adhesive layer. The adhesive should have a melting point above 100°C to avoid any delamination or dissolving during the brewing process.
[053] In order to maintain the quality of the product within a beverage capsule, the lidding structure should provide suitable moisture barrier. The adhesive layer may have a moisture vapor transmission rate in a range of from 5 g/m2d to 50 g/m2d according to ASTM F1249. In embodiments of the lidding structure that include a thermoplastic-based adhesive layer that is providing moisture barrier, it may be important that the adhesive layer is coextensive with the paper layers.
[054] The lidding structure may have a total composition that includes a cellulose content in a range of from 80 % to 99 %, or from 90 % to 99 %, by weight. The lidding structure may have a total composition that includes a cellulose content of at least 80 % or at least 90 %, by weight. The lidding structure should have a total composition that includes a renewable material content in a range of from 80 % to 99 %, or from 90 % to 99 %, by weight.
[055] The lidding structure may have an oxygen transmission rate of in a range of from 0.5 mL/m2/day to 2 mL/m2/day, according to ASTM F1927.
EXAMPLES AND DATA
[056] Three lidding structures were produced and tested to evaluate the effect of the type of filtering medium used. The first, Sample A, included a lamination of a barrier paper and a PLA non-woven material. The second, Sample B, included a lamination of a barrier paper and a sealable filter paper having PLA fibers. The third, Sample C, included a lamination of a barrier paper and an all cellulose based filter paper. These samples were tested in a 100 mL coffee extraction process, specifically measuring the extraction time, the water wasted and the quantity extracted. Results are shown in Table 1 .
Table 1 : Coffee Extraction Testing for Filtering Medium Variables
Figure imgf000014_0001
Figure imgf000015_0001
[057] An acceptable extraction time for this type of extraction process is between 20 and 40 seconds, which each of the samples met. However, it is noted that Sample C, including the cellulose based filter paper, demonstrated the fastest extraction time.
[058] The water wasted is the amount of water used in the process that was not part of the extracted beverage quantity. The extracted quantity should be as close as possible to the target 100 mL.
[059] From the results shown in Table 1 , it is noticed that Sample A has a markedly higher waste volume and a correspondingly low extracted quantity. This is indicative of a high extraction pressure and an uncontrolled flow during extraction. Sample B has a much better (lower) waste value, but still demonstrates a rather low extracted quantity. Comparatively, Sample C, using the cellulose based filter paper, has a high extracted quantity of 86 mL, which is close to non-compostable brewing capsules used today, which have an extracted quantity of just over 90 mL in this extraction test.

Claims

What is claimed is:
1 . A lidding structure for a beverage capsule comprising: a cellulose-based paper located at a first surface of the lidding structure; a filter paper located at a second surface of the lidding structure; and an adhesive layer located between the cellulose-based paper and the filter paper; wherein the adhesive layer has a basis weight in a range of from 1 g/m2 to 8 g/m2; and the lidding structure has a total composition including a cellulose content in a range of from 80 % to 99 %, by weight.
2. The lidding structure for a beverage capsule according to claim 1 wherein the filter paper is non-sealable to itself.
3. The lidding structure for a beverage capsule according to claim 1 or 2 wherein the filter paper consists of cellulose fibers.
4. The lidding structure for a beverage capsule according to any previous claim wherein the filter paper has a basis weight in a range of from 10 g/m2 to 40 g/m2.
5. The lidding structure for a beverage capsule according to any previous claim wherein the filter paper has a Bendtsen roughness of less than 4000 mL/min, according to ISO 8791-2.
6. The lidding structure for a beverage capsule according to any previous claim wherein the cellulose-based paper has an oxygen transmission rate in a range of from 0.5 mL/m2/day to 2 mL/m2/day, according to ASTM F1927.
7. The lidding structure for a beverage capsule according to any previous claim wherein the cellulose-based paper comprises a microf ibrillated cellulose paper.
8. The lidding structure for a beverage capsule according to any previous claim wherein the cellulose-based paper comprises a basis weight in a range of from 40 g/m2 to 90 g/m2.
9. The lidding structure for a beverage capsule according to any previous claim wherein the adhesive layer comprises a thermoplastic-based adhesive.
10. The lidding structure for a beverage capsule according to claim 9 wherein the thermoplastic-based adhesive comprises one or more of acrylic based polymers, vinyl acetate copolymers and ethylene waxes.
11 . The lidding structure for a beverage capsule according to claim 9 or 10 wherein the thermoplastic-based adhesive comprises a moisture vapor transmission rate in a range of from 5 g/m2d to 50 g/m2d according to ASTM F1249.
12. The lidding structure for a beverage capsule according to any previous claim wherein the total composition includes a cellulose content between 90 % and 99 %, by weight.
13. The lidding structure for a beverage capsule according to any previous claim wherein the adhesive layer is directly connected to the cellulose-based paper and the thermoplastic-based adhesive layer is directly connected to the filter paper.
14. The lidding structure for a beverage capsule according to any previous claim wherein the cellulose-based paper, the filter paper and the adhesive layer are each coextensive with each other.
15. The lidding structure for a beverage capsule according to any previous claim wherein the total composition includes a renewable raw material content in a range of from 80 % to 99 %, by weight.
16. A beverage capsule comprising a lidding structure according to any previous claim and a container comprising a compostable polymer.
17. The beverage capsule according to claim 16 wherein the compostable polymer is one or more of PLA, PHA, or PBS.
18. The beverage capsule according to claim 16 or 17 wherein the filter paper of the lidding structure is hermetically sealed to the compostable polymer of the container.
19. The beverage capsule according to any of claims 16 through 18 further comprising a dry beverage mix located between the container and the lidding structure.
20. The beverage capsule according to any of claims 16 through 19 wherein the compostable polymer of the container is located within the pores of the filter paper.
21 . The beverage capsule according to any of claims 16 through 20 wherein the beverage capsule is compostable according to standard EN 13432.
PCT/US2022/035061 2022-06-27 2022-06-27 Compostable barrier lids and beverage capsules WO2024005773A1 (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018197676A1 (en) * 2017-04-28 2018-11-01 Ahlstrom-Munksjö Oyj Compostable lid comprising an oxygen barrier layer for sealing a capsule and capsule sealed by the lid
WO2022053339A1 (en) * 2020-09-11 2022-03-17 Societe Des Produits Nestle S.A. Compostable top lid structure for a beverage preparation capsule

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018197676A1 (en) * 2017-04-28 2018-11-01 Ahlstrom-Munksjö Oyj Compostable lid comprising an oxygen barrier layer for sealing a capsule and capsule sealed by the lid
WO2022053339A1 (en) * 2020-09-11 2022-03-17 Societe Des Produits Nestle S.A. Compostable top lid structure for a beverage preparation capsule

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