US20150225099A1 - Method and Apparatus for Fabricating a Beverage Capsule - Google Patents

Method and Apparatus for Fabricating a Beverage Capsule Download PDF

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Publication number
US20150225099A1
US20150225099A1 US14/411,963 US201314411963A US2015225099A1 US 20150225099 A1 US20150225099 A1 US 20150225099A1 US 201314411963 A US201314411963 A US 201314411963A US 2015225099 A1 US2015225099 A1 US 2015225099A1
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US
United States
Prior art keywords
flange
wall member
vacuum
regions
cavity
Prior art date
Legal status (The legal status 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 status listed.)
Abandoned
Application number
US14/411,963
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English (en)
Inventor
Olivier Villain
Patricia Ann Mathias
Paul Eichler
Céline Sarrazin-Horisberger
Martin Von Blittersdorff
Abdenour Djamer
Ulrich Kessler
Christian Guenat
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Nestec SA
Original Assignee
Nestec SA
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
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Assigned to NESTEC S.A. reassignment NESTEC S.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EICHLER, PAUL, SARRAZIN-HORISBERGER, Céline, MATHIAS, PATRICIA ANN, VON BLITTERSDORFF, Martin, DJAMER, Abdenour, KESSLER, ULRICH, VILLAIN, OLIVIER
Publication of US20150225099A1 publication Critical patent/US20150225099A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B29/00—Packaging of materials presenting special problems
    • B65B29/02—Packaging of substances, e.g. tea, which are intended to be infused in the package
    • B65B29/022—Packaging of substances, e.g. tea, which are intended to be infused in the package packaging infusion material into capsules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B31/00—Packaging articles or materials under special atmospheric or gaseous conditions; Adding propellants to aerosol containers
    • B65B31/04—Evacuating, pressurising or gasifying filled containers or wrappers by means of nozzles through which air or other gas, e.g. an inert gas, is withdrawn or supplied
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B1/00—Packaging fluent solid material, e.g. powders, granular or loose fibrous material, loose masses of small articles, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
    • B65B1/02—Machines characterised by the incorporation of means for making the containers or receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B1/00—Packaging fluent solid material, e.g. powders, granular or loose fibrous material, loose masses of small articles, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
    • B65B1/04—Methods of, or means for, filling the material into the containers or receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B29/00—Packaging of materials presenting special problems
    • B65B29/02—Packaging of substances, e.g. tea, which are intended to be infused in the package
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B31/00—Packaging articles or materials under special atmospheric or gaseous conditions; Adding propellants to aerosol containers
    • B65B31/02—Filling, closing, or filling and closing, containers or wrappers in chambers maintained under vacuum or superatmospheric pressure or containing a special atmosphere, e.g. of inert gas
    • B65B31/025—Filling, closing, or filling and closing, containers or wrappers in chambers maintained under vacuum or superatmospheric pressure or containing a special atmosphere, e.g. of inert gas specially adapted for rigid or semi-rigid containers
    • B65B31/028—Filling, closing, or filling and closing, containers or wrappers in chambers maintained under vacuum or superatmospheric pressure or containing a special atmosphere, e.g. of inert gas specially adapted for rigid or semi-rigid containers closed by a lid sealed to the upper rim of the container, e.g. tray-like container
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
    • B65B51/10—Applying or generating heat or pressure or combinations thereof
    • B65B51/22—Applying or generating heat or pressure or combinations thereof by friction or ultrasonic or high-frequency electrical means, i.e. by friction or ultrasonic or induction welding
    • B65B51/225—Applying or generating heat or pressure or combinations thereof by friction or ultrasonic or high-frequency electrical means, i.e. by friction or ultrasonic or induction welding by ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B7/00—Closing containers or receptacles after filling
    • B65B7/16—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons
    • B65B7/162—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by feeding web material to securing means
    • B65B7/164—Securing by heat-sealing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS 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
    • B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/70—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for
    • B65D85/804—Disposable containers or packages with contents which are mixed, infused or dissolved in situ, i.e. without having been previously removed from the package
    • B65D85/8043—Packages adapted to allow liquid to pass through the contents

Definitions

  • the presently disclosed and/or claimed inventive concept(s) relates generally to a method for the fabrication of a beverage capsule for use in a beverage machine. It also relates to an apparatus for performing said method, as well as the beverage capsules so produced. In particular, the presently disclosed and/or claimed inventive concept(s) relates to such capsules as adapted for coffee beverage.
  • 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.
  • Packaging coffee in sealed containers will protect it from the surrounding air, resulting in greater shelf life and optimal flavor and aroma during consumption.
  • Such beverage capsules may be hermetically-sealed, preventing degradation of the beverage ingredient(s) within prior to consumption.
  • such edible granules may comprise ground roasted coffee, soluble coffee, powdered milk, powdered cocoa, loose tea leaves and/or other herbs, broth, or any combination thereof.
  • the beverage capsule is placed into the beverage production machine, which introduces hot water into the beverage capsule and dispenses the resulting beverage into a container for consumption. While this document refers to a “capsule,” it is understood that other terms, such as “pod,” “cartridge,” or “packet,” may be employed instead.
  • beverage capsules under modified atmosphere (e.g. an atmosphere saturated with nitrogen or carbon dioxide) or under vacuum.
  • a vacuum may be applied to the capsule when the capsule is filled with a beverage ingredient to remove the air from within.
  • the beverage capsule is formed of gas-tight packaging materials and hermetically sealed to preserve the vacuum therein. In this way, any oxygen present in the capsule is removed prior to sealing and the edible granules are thus protected from degradation prior to consumption.
  • the edible granules may also become entrained between the sealing walls of the capsule, e.g. between the body and the capsule sealing means, preventing the latter from being properly bonded to the former. This compromises the strength and aesthetic quality of the beverage capsule seal, and by extension the protection of the edible granules within the seal of the beverage capsule.
  • the entrainment of edible granules may also result in tearing of the seal of the beverage capsule due to the pressure increase within the capsule during the beverage preparation process. This can result in the rupture of the capsule and the liberation of wet coffee powder through the broken seal, soiling the beverage machine and producing a foul-tasting beverage.
  • WO2008129350 refers to a machine for packaging capsules also in a vacuum and/or in a controlled atmosphere. After filling with coffee, the capsules are partially closed by hermetic film. Then, a vacuum is formed inside the capsules and sealed by a thermo-sealing vacuum device.
  • U.S. Pat. No. 3,775,932 refers to a packaging apparatus for making vacuum packages of a product by sealing of two superimposed films together with the product contained therebetween. A vacuum is drawn by a vacuum tube connection in the partially sealed package whereby the edge of the packaging film is captured between the sealing head and a resilient strip with the edge of the superimposed film being free.
  • WO2010007633 refers to a machine for packaging products, in particular capsules for machines for delivering infusion beverages.
  • a vacuum bell provides vacuum around each capsule to be welded.
  • vacuum compensating means take care of inserting gas, in particular nitrogen, inside each capsule in such a way to compensate the presence of vacuum.
  • the welding means take care of welding the aluminium sheet onto the edge of the respective capsule.
  • U.S. Pat. No. 4,069,349 refers to a process for vacuum packaging of roasted ground coffee in pouches.
  • the pouches are partially sealed, with a tortuous unsealed passage, and then stored for a predetermined period of time to permit the gases to evolve from the pouches and then sealing the pouches to prevent further gaseous passage to and from the product.
  • the two means may be disposed so that the attachment means is within the means for cutting the second wall member. This conserves space in the apparatus, effectively placing the two components in the space of one.
  • the vacuum application and sealing means may be adapted to act upon the first and second wall members simultaneously, thereby reducing the time required to carry out the attachment and cutting steps. This feature will thereby improve the output and efficiency of the apparatus, while simultaneously making it more compact and space-efficient.
  • FIG. 1 is a series of orthogonal section views depicting an attachment means, a cutting means, a vacuum-application means, and a sealing means;
  • FIG. 2 is a series of views of attachment apparatuses in four different configurations.
  • FIG. 3 is a flowchart depicting the method of the presently disclosed and/or claimed inventive concept(s) as integrated into a process for the fabrication of beverage capsules, said process comprising a series of steps.
  • the presently disclosed and/or claimed inventive concept(s) includes a method for the fabrication of beverage capsules in which edible granules may be sealed under vacuum within a beverage capsule, while reducing or eliminating the aspiration of such edible granules and thereby producing a seal of high integrity.
  • a first aspect of the presently disclosed and/or claimed inventive concept(s) is directed to a method for fabricating a beverage capsule, comprising the steps of providing a first wall member, said first wall member at least partially delimiting a cavity and having a flange disposed circumferentially about an open end communicating with said cavity; providing a quantity of edible granules within said cavity of said first wall member; positioning a second wall member upon said flange and said open end of said first wall member; attaching said second wall member to said flange at at least two regions of said flange, thereby dividing the flange circumferentially into at least two attached regions and at least two unattached regions; applying a vacuum between said first and second wall members, thereby evacuating the gas from within said cavity and said edible granules through said at least two unattached regions of the flange and creating a vacuum within said cavity; and sealing said first and second wall members along said flange, thereby maintaining said vacuum within said cavity.
  • the attachment of the second wall member to the flange of the first wall member along at least two regions prevents the second wall member from moving in any direction along the flange when a vacuum is applied.
  • This is advantageous because the attachment of the second wall member to at least two regions of the flange of the first wall member will reduce or eliminate the aspiration of edible granules during the application of the vacuum.
  • This also prevents the second wall member from being displaced (e.g. moved off-center), deformed, or folded prior to the sealing step, preventing the formation of wrinkles, creases, plies, or other undesirable forms in the second wall member.
  • the second wall member is attached to said flange at a plurality of regions of said flange, thereby dividing the flange circumferentially into a plurality of attached regions and a plurality of unattached regions; and the vacuum is applied between said first and second wall members, thereby evacuating the gas from within said cavity and said edible granules through said plurality of unattached regions of the flange, thereby creating a vacuum in said cavity.
  • the attachment of the second wall member to a plurality of regions of the flange of the first wall member will reduce or eliminate the aspiration of edible granules during the application of the vacuum.
  • the attached regions prevent the edible granules from leaving the capsule.
  • the gas within the cavity and edible granules may still be removed, as it may still flow through the spaces between the flange and the second wall member at the unattached regions.
  • the edible granules may be confined to the first wall member during the application of the vacuum, the quantity of such edible granules which are aspirated into the vacuum-sealing apparatus is greatly reduced.
  • the performance of this method is thereby rendered more cost-effective and reliable, while the quality of the beverage capsules so produced is simultaneously improved.
  • the entrainment of edible granules between the second wall member and the flange of the first wall member is similarly reduced or eliminated. Since the edible granules no longer interfere with the interface between the wall members, the strength and aesthetic quality of the seal between the two are improved.
  • the physical properties of the beverage capsule are thus optimized, providing more effective protection to the edible granules and better preserving the flavor and aroma of the beverage produced from them.
  • the method permits the above-mentioned advantages to be realized while providing vacuum and sealing the beverage capsules individually.
  • the attachment of the second wall member to the flange of the first wall member prior to the application of a vacuum and the sealing of the beverage capsule permits a vacuum to be rapidly applied while still maintaining a high level of strength and aesthetic quality in the sealed beverage capsules. Since the vacuum is applied only to one beverage capsule at a time, the sealing of each beverage capsule may be individually monitored and controlled. The sealing process may thus be made adaptable so that each capsule is given a seal of the highest possible quality. In this way, the efficiency of the method is maximized while simultaneously ensuring that the beverage capsules so fabricated are of the highest possible quality.
  • the method is characterized in that said first wall member is a self-supporting capsule body and said second wall member is a flexible membrane.
  • first and second wall members in the form of a self-supporting capsule body and a flexible membrane facilitate the provision of coffee within the capsule body and the sealing of the membrane upon the flange.
  • a self-supporting capsule body will give structural strength to the unsealed beverage capsule, facilitating handling during the manufacturing process.
  • the steps for attaching and sealing said second wall member onto said flange are performed by heat sealing.
  • Heat sealing processes can rapidly produce seals which are generally airtight, durable, flexible, and sanitary.
  • Heat-sealing means may also be integrated into an apparatus embodying this method, such as by the incorporation of hot air jets, electric resistance heaters, or the like. Heat sealing processes may also be adapted to work with a variety of materials, improving the compatibility of this method.
  • the bonds created between the second wall member and the flange of the first wall member during the attachment step will be substantially identical to the seal created during the sealing step. This results in a seal which is uniform across its entire surface, without any areas of diminished strength or other undesirable variations.
  • this feature is advantageous in that the first and second wall members need only be suitable for a single type of bonding process rather than two types, increasing the selection of possible materials for the components of the beverage capsule. This feature, therefore, makes the presently disclosed and/or claimed inventive concept(s) simpler and easier to practice while producing improved results.
  • the steps for attaching and sealing of said second wall member onto said flange are performed by ultrasonic welding.
  • ultrasonic welding can rapidly produce seals which are generally airtight, durable, flexible, and sanitary.
  • Ultrasonic welding is also advantageous in that it does not require the first and second wall members to be heated in order to create the seal, permitting these components to be fabricated from materials which may not be suitable for heat sealing. The versatility of the presently disclosed and/or claimed inventive concept(s) is thereby improved.
  • the second wall member is attached to said flange over an area comprising between 25% and 90%, such as but not limited to, between 30% and 75% of the total sealed surface of said flange of said first wall member.
  • the edible granules are provided within the cavity in loose form.
  • the application of vacuum and sealing while maintaining the vacuum within the cavity are carried out immediately after the attaching of the second wall member to the flange and dividing the flange into the at least two or a plurality of attached and unattached regions.
  • immediately it is meant that there is no pause higher than a few seconds allowing the edible granule to significantly loose gas and consequently aroma.
  • the presently disclosed and/or claimed inventive concept(s) is directed to a beverage capsule fabricated as described above.
  • the presently disclosed and/or claimed inventive concept(s) is directed to an apparatus for the fabrication of a beverage capsule, comprising an attachment means, said attachment means being configured to attach a first wall member to a second wall member at a flange disposed circumferentially about an open end of said first wall member, said attachment being situated over at least two regions of said flange and thereby dividing the flange into at least two attached regions and at least two unattached regions, said first wall member at least partially delimiting a cavity in communication with said open end and being provided with a quantity of edible granules within said cavity; a vacuum application means, said vacuum application means being provided with a receptacle adapted for airtight communication with said first and second wall members, and being further configured to evacuate the gas from said first wall member and edible granules through the at least two unattached regions of the flange, thereby creating a vacuum within said cavity; and a sealing means, said sealing means being configured so as to create a seal between
  • the first wall member is a self-supporting capsule body defining said cavity and said flange and the second wall member is a flexible membrane.
  • the membrane may have a thickness comprised between 10 and 250 microns, such as but not limited to, between 30 and 100 microns.
  • the membrane contains at least one layer fabricated from a material having gas barrier properties, such as aluminum.
  • the membrane also comprises a sealant layer comprised of a material such as polypropylene.
  • the apparatus is characterized in that the attachment means attaches said second wall member to said flange over a plurality of regions of the flange, thereby dividing the flange into a plurality of attached regions and a plurality of unattached regions and the vacuum application means is configured to evacuate the gas from said first wall member and edible granules through the at least one unattached region of the flange.
  • the attachment means comprises a plurality of faces disposed perpendicular to and in radial symmetry about an axis of said attachment means, and which are configured to attach said second wall member to said flange of said first wall member over a plurality of regions corresponding to said plurality of faces.
  • said vacuum-application means and said sealing means are disposed coaxially about a longitudinal axis, said vacuum-generating means being adapted to translate along said longitudinal axis relative to said sealing means.
  • sealing means may be disposed within the vacuum application means. This conserves space in the apparatus, effectively placing the two means in the space of one. This is also advantageous in that the steps for vacuum application and sealing may be performed simultaneously as described above. This feature will thereby improve the output and efficiency of the apparatus, while simultaneously making it more compact and space-efficient.
  • the apparatus further comprises a means for cutting said second wall member to substantially match the outline of said flange and open end of said first wall member.
  • said means for cutting said second wall member is disposed about said attachment means, said attachment means and means for cutting said second wall member being coaxial about a longitudinal axis, and said cutting means being adapted to translate along said longitudinal axis relative to said sealing means.
  • FIG. 1 is a sequence of section views depicting the sealing of a beverage capsule according to the presently disclosed and/or claimed inventive concept(s).
  • FIG. 1 depicts the attachment and cutting steps in views A through D, and the vacuum application and sealing steps in views E through H. Portions of the apparatus are omitted from each of these views for purposes of clarity.
  • View A depicts an attachment means 100 and a cutting means 101 disposed in a first position, prior to the start of an attachment step.
  • the attachment means 100 and the cutting means 101 are generally tubular and coaxial about the first longitudinal axis 102 .
  • the cutting means 101 will be disposed around and capable of translation relative to the attachment means 100 , as depicted here.
  • a capsule body 103 is positioned within the base plate 104 , which is provided with a capsule seat 105 in which the capsule body 103 is positioned.
  • the base plate 104 is configured to be mobile, facilitating a high rate of production of beverage capsules. This mobile configuration may comprise such means as a conveyor belt system or rotating turret, for example.
  • the capsule body 103 is positioned beneath the attachment means 100 and cutting means 101 so as to be coaxial with them about the first longitudinal axis 102 .
  • the capsule body 103 defines a cavity 106 , in which a predetermined quantity of ground coffee powder 107 is provided.
  • the capsule body 103 is substantially cup-shaped, and is provided with an open end 108 communicating with said cavity 106 .
  • the capsule body 103 is further provided with a flange 109 , disposed about the circumference of the capsule body 103 at the open end 108 .
  • the capsule body 103 is fabricated from a formable material such as aluminum, plastic, starch, cardboard, or combination thereof.
  • a gas barrier layer may be incorporated therein to prevent the entry of oxygen.
  • the gas barrier may comprise a coating, film, or layer of aluminum, ethylene vinyl alcohol, polyamide, oxides of aluminum or silicon, or combinations thereof.
  • the capsule body 103 is formed of deep-drawn aluminum.
  • the capsule body 103 is formed of deep-drawn polypropylene and aluminum.
  • the capsule body 103 is thermoformed from a combination of polypropylene, ethylene vinyl alcohol, and polyethylene terephthalate.
  • the flange 109 and the capsule seat 105 are configured so that the capsule body 103 protrudes through the base plate 104 , with the flange 109 resting directly on the base plate 104 and substantially the entire beverage capsule 103 being disposed beneath the base plate 104 .
  • the capsule seat may be configured as a cup, in which the capsule body is seated.
  • a portion of membrane material 110 is disposed between the cutting means 101 and the base plate 104 .
  • said membrane material 110 is provided in the form of a continuous sheet or web, which may be fed into the apparatus by techniques adapted from those known in the art of materials handling.
  • the membrane material 110 is flexible, permitting moderate elastic deformation.
  • the membrane material 110 may have a thickness between 10 and 250 microns, such as but not limited to, between 30 and 100 microns.
  • the membrane material 110 comprises at least a base layer fabricated of aluminum, polyester (e.g. PET or PLA), polyolefin(s), polyamide, starch, paper, or any combination thereof.
  • the base layer is formed of a laminate comprising two or more sub-layers of these materials.
  • the base layer may comprise a sub-layer which acts as a gas barrier, if none of the other sub-layers are of a material which is impermeable to gas.
  • the gas barrier sub-layer is fabricated from a gas-impermeable material such as aluminum, ethylene vinyl alcohol, polyamide, oxides of aluminum or silicon, or combinations thereof.
  • the membrane material 110 also comprises a sealant layer, e.g. polypropylene, disposed to create a seal with the capsule body 103 .
  • the membrane material 110 is an aluminum layer between 25 and 40 microns.
  • the membrane material 110 comprises a base layer with two sub-layers: an external sub-layer made of PET and an internal sub-layer made of aluminum.
  • the aluminum sub-layer serves the function of preventing undesirable transmission of light, moisture, and oxygen.
  • the membrane material 110 comprises three sub-layers: an external sub-layer of PET 5 to 50 microns thick, a middle sub-layer of aluminum 5 to 20 microns thick, and an internal sub-layer of cast polypropylene 5 to 50 microns thick.
  • View B depicts the apparatus in a second position, during a cutting step.
  • the cutting means 101 is advanced downward along the first longitudinal axis 102 into the membrane material 110 .
  • the cutting means 101 is sharpened along its peripheral edge 111 so as to cut the membrane material 110 when pressed into it.
  • alternate configurations such as a hot-knife apparatus, may be preferable for certain compositions of heat-sensitive membrane material.
  • the cutting means 101 is advanced through the membrane material 110 , cutting a membrane 112 from the membrane material 110 .
  • View C depicts the apparatus in a third position, during an attachment step.
  • the attachment means 100 At the lower end 113 of the attachment means 100 are disposed a plurality of faces disposed substantially perpendicular to the longitudinal axis 102 , which are pressed into the membrane 112 .
  • the attachment means 100 is advanced so that the lower end 113 presses the membrane 112 into the flange 109 over a plurality of regions corresponding to the aforementioned faces.
  • the attachment means 100 is configured to attach the membrane 112 to the flange 109 over the regions where the faces of the lower end 113 press said membrane 112 into the flange 109 of the capsule body 103 .
  • the attachment of the membrane 112 to the flange 109 of the capsule body 103 is achieved by heat-sealing; though in other, non-limiting embodiments, alternate techniques such as ultrasonic welding may be preferred.
  • the attachment means 100 is therefore furnished with appropriate means for attaching the membrane 112 to the flange 109 during the attachment step.
  • such means may comprise an electrical resistance heater, hot air jet, or ultrasonic welding horn. This will make the apparatus more compact and space-efficient.
  • Said regions of the flange 109 corresponding to the faces of the lower end 113 of the attachment means 100 will comprise a portion of the total surface of the flange 109 .
  • the cavity 106 of the capsule body 103 thereby remains in communication with the surrounding atmosphere, via the spaces between the flange 109 and the membrane 112 where the membrane 112 remains unattached to the flange 109 .
  • View D depicts the apparatus in a fourth position, after the completion of the attachment step.
  • the attachment means 100 and cutting means 101 are withdrawn from the capsule body 103 and membrane 112 .
  • the scrap membrane material 110 may be removed, while the base plate 104 is advanced in direction 114 to both place the current beverage capsule in position for vacuum sealing and bring the next beverage capsule into position for the attachment and cutting steps.
  • the step for cutting the membrane 112 as depicted in View B and the step for attaching said membrane 112 to the flange 109 as depicted in View C are performed sequentially but in a continuous movement of descent of the cutting and attachment means 101 , 100 .
  • a slight vacuum is further applied through the attachment means to maintain the membrane 112 in coaxial position in axis 102 during the cutting and attachment steps. This is advantageous, in that it minimizes the time to fabricate a capsule and thus increases the rate at which capsules are produced.
  • View E depicts the apparatus in a fifth position, prior to the start of a sealing step.
  • the cutting and attachment means depicted in the previous steps are omitted here for clarity; however, the cutting and attachment means are ideally disposed adjacent or in close proximity to the vacuum-application means 115 and sealing means 116 , making the apparatus more compact and space-efficient.
  • the vacuum-application means 115 and the sealing means 116 are tubular and disposed coaxially about the second longitudinal axis 117 .
  • the sealing means 116 is in the form of a hollow cylinder, of approximately the same width and diameter of the flange 109 of the beverage capsule 103 .
  • the vacuum-application means 115 is also in the form of a hollow cylinder, and is provided with a means for creating a vacuum within.
  • the vacuum-application means 115 is configured so as to be capable of translation relative to the sealing means 116 along their shared second longitudinal axis 117 .
  • the base plate 104 is advanced in the direction 114 until the capsule body 103 and membrane 112 are also coaxial with the vacuum-application means 115 and the sealing means 116 about the second longitudinal axis 117 .
  • the capsule body 103 and membrane 112 are thus positioned in a centered position directly below the vacuum-application means 115 and sealing means 116 .
  • View F depicts the apparatus in a sixth position, during a vacuum-application step.
  • the vacuum-application means 115 have been advanced so as to create an airtight seal between the mouth 118 of the vacuum-application means 115 and the flange 109 of the capsule body 103 .
  • a vacuum 119 is applied to the capsule body 103 through the vacuum-application means 115 , reducing the pressure in the cavity 106 of the capsule body 103 below atmospheric pressure.
  • the vacuum 119 causes the gas within the cavity 106 of the capsule body 103 to be drawn out through the plurality of spaces between the flange 109 and the membrane 112 , which are defined by the regions where said membrane 112 remains unattached to said flange 109 .
  • the gas can be air or any inert gas, such as nitrogen, CO 2 , or any combination thereof. In this way, the cavity 106 of the capsule body 107 is voided of gas and a vacuum created within it.
  • the vacuum-application step is configured so that the vacuum may be rapidly applied to the capsule body 103 while avoiding sucking the coffee powder 107 from the cavity 106 .
  • the rapid application of a vacuum to a beverage capsule may cause some of the coffee powder within to be sucked out, which may result in damage to the apparatus from aspirated coffee powder.
  • the coffee powder may also become entrained between the sealing surfaces of the beverage capsule, weakening the seal and diminishing its aesthetic properties.
  • the application of vacuum may also cause the sealing means to move, further compromising seal integrity.
  • the attachment of the membrane 112 to the flange 109 of the capsule body 103 over a plurality of regions will prevents the aspiration and entrainment of the coffee powder 107 between the flange 109 and the membrane 112 , as well as prevent the displacement of the membrane relative to the capsule body during the application of the vacuum 119 .
  • the integrity of the beverage capsule seal and the reliability of the sealing apparatus are thus preserved even when the vacuum is applied very rapidly, permitting higher-quality beverage capsules to be produced at a faster rate.
  • the vacuum-application step is also configured to enable the conditions within the capsule to be monitored as the vacuum 119 is applied.
  • the vacuum-application means permits the rapid application of the vacuum 119 to a single capsule body 103 , rather than the slower application of a vacuum to a group of capsule bodies in a vacuum chamber.
  • View G depicts the apparatus in a seventh position, during a sealing step.
  • the mouth 118 of the vacuum-application means 115 is kept in contact with the flange 109 of the capsule body 103 , such that the vacuum within the cavity 106 of the capsule body 103 is maintained.
  • the sealing means 116 is provided with a means for creating a seal between the membrane 119 and the flange 109 of the capsule body 103 , similar to the attachment means as discussed above.
  • this may comprise such means as an electrical resistance heater, hot-air jets, or ultrasonic welding horn.
  • the sealing means 116 is advanced into contact with the membrane 112 , pressing into it along the sealing edge 120 disposed at an end of said sealing means 116 .
  • the membrane 112 is pressed into the flange 109 by the sealing means 116 , thereby bonding the remaining unattached regions of the membrane 112 to the surface of the flange 109 and sealing the cavity 106 of the capsule body 103 . While the remaining unattached regions of the membrane are bonded, the bond of the attached regions created during the attachment step may be renewed.
  • the air-tight hermetic seal created between the flange 109 and the membrane 112 will thereby preserve the vacuum in the cavity 106 of the capsule body 103 , protecting the coffee powder 107 from exposure to air and subsequent loss of flavor and aroma.
  • View H depicts the sealed beverage capsule after the completion of the sealing step.
  • the sealing means 116 is withdrawn to allow the bond to solidify.
  • the vacuum is stopped in the vacuum means, exposing the capsule body 103 and membrane 112 to atmospheric pressure and causing the membrane 112 to take a concave form as depicted.
  • the vacuum-application means 115 is withdrawn.
  • the vacuum which was applied to the capsule body 103 in an earlier step is preserved therein by the seal between the flange 109 and the membrane 112 .
  • the base plate 104 is then moved off in direction 114 , removing the capsule to be packaged and distributed and bringing the next capsule into position for vacuum sealing.
  • the edible granules are of a substance that tends to evolve a gas.
  • Such substances notably include roasted coffee, especially ground roasted coffee powder as described here.
  • the coffee powder 107 will evolve gas for a period of time after the roasting process is completed, a process known in the art as “degassing.” As the coffee powder 107 within the beverage capsule degasses, the gases which are evolved are kept within the cavity 106 of the beverage capsule by the membrane 112 , the capsule body 103 , and the hermetic seal between them.
  • the vacuum which is sealed into the beverage capsule thus partially offsets the pressure generated by the gases evolved from the coffee powder 107 .
  • the degree to which the vacuum offsets the evolved gases may vary from embodiment to embodiment, depending on the volume of the beverage capsule, the mass of coffee provided within, and the type and degree of roast of the coffee powder itself. In any case, the vacuum within the beverage capsule compensates for the degassing at least to the extent that the evolved gas is prevented from compromising the structural integrity of the beverage capsule and its hermetic properties.
  • the initial vacuum pressure of the capsule immediately after the sealing step will be between 300 and 600 mbar, such as but not limited to, between 400 and 500 mbar.
  • the gases evolved by the coffee powder during degassing will continue to accumulate in the cavity 106 of the beverage capsule, causing the internal pressure of the beverage capsule to rise above atmospheric pressure in approximately 5 hours and reach equilibrium at between 1050 and 1600 mbar, such as but not limited to, between 1050 and 1350 mbar, in approximately 72 hours.
  • the method may be configured so that all, or substantially all, of the degassing occurs within the beverage capsule after it has been sealed. While the pressure within the beverage capsule will be negative at time of sealing, the evolved gases will rapidly increase the pressure within the capsules. In a particular, non-limiting embodiment, the capsule will rise above atmospheric pressure in less than 5 hours and stabilize in approximately 72 hours.
  • FIG. 2 is a series of views depicting several configurations for the attachment means.
  • the attachment means comprises at its bottom end a plurality of faces, which are pressed into the membrane to attach it to the flange of the capsule body over a plurality of regions corresponding to said faces.
  • FIG. 2A and 2B depict an orthogonal view and a perspective view, respectively, of an attachment means 200 .
  • the attachment means 200 is substantially in the form of a hollow cylinder.
  • Two slots 201 have been provided in the attachment means 200 , with the result that the end of the attachment means 200 is divided into two faces 202 and two voids 203 .
  • the membrane When pressed into a membrane during the attachment step as described above, the membrane will be attached to a flange of a capsule body over the portion of the surface of the flange corresponding to the faces 202 of a first kind.
  • the membrane will remain unattached and permit fluid communication between the cavity of the capsule body and the surrounding atmosphere through the unattached regions between the membrane and flange defined by the voids 203 of a first kind.
  • FIG. 2C depicts an orthogonal view of an alternate configuration for the attachment means, comprising four faces 204 of a second kind and four voids 205 of a second kind.
  • Such an attachment means will attach a membrane to a flange of a capsule body over a plurality of regions corresponding to each of the four faces 204 of a second kind, while leaving the regions of the membrane corresponding to the four voids 205 of a second kind unattached.
  • FIG. 2D depicts an orthogonal view of another alternate configuration for the attachment means, provided with eight faces 206 of a third kind and separated by eight voids 207 of a third kind.
  • the faces 206 of a third kind will define the region over which a membrane is attached to the flange of a capsule body, and the voids 207 of a third kind defining where it is unattached.
  • FIG. 2E depicts an orthogonal view of another alternate configuration for the attachment means, provided with eight faces 208 of a fourth kind which are separated by eight voids 209 of a fourth kind.
  • the faces 208 of a fourth kind are much smaller than the faces 206 of a third kind, while the voids 209 of a fourth kind are much larger than the voids 207 of a third kind.
  • the proportion of the flange of a capsule body to which a membrane will be attached by the attachment device in FIG. 2E is much lower than would be achieved by the attachment device of FIG. 2D , with a corresponding increase in the size of the regions of the flange to which the membrane remains unattached.
  • attachment devices may in this way be configured to best suit the particular application in which the attachment device is to be employed.
  • the attachment devices are altered by adjusting their number and size; however, in other embodiments it may be advantageous to modify other elements of their form and geometry such as shape, thickness, or placement about the lower end of the attachment means.
  • the attachment means may reduce the time required to apply the vacuum to the capsule body while still minimizing the aspiration and entrainment of the coffee powder or other edible granules contained within the capsule body.
  • the sealing of the beverage capsules may thus be optimized to achieve a maximum output at a minimum cost.
  • FIG. 3 is a flowchart depicting a process for the fabrication of beverage capsules, said operation comprising a series of elements.
  • the first step of the operation is Capsule Body Destacking 300 .
  • the empty capsule bodies are generally stored stacked atop each other when stored before use, and so must be separated before they can be further processed.
  • the capsule bodies are separated from each other and placed in the proper orientation to continue in the process.
  • the Coffee Preparation Process 301 furnishes a supply of coffee powder for packaging within the beverage capsules.
  • coffee beans are roasted to the desired degree of roasting and then ground to the desired degree of fineness.
  • the gases generated within the coffee beans during roasting are evolved from the coffee. Some degassing will occur between the roasting of the coffee and the sealing of the beverage capsule.
  • the duration between the grinding of the coffee and its provision within the beverage capsule is less than ten minutes; in this way the flavor and aroma of the beverage ultimately produced from the beverage capsule is best preserved.
  • a portion of the coffee powder provided by the Coffee Preparation Process 301 is placed within the capsule body and densified, so that the coffee is settled within the capsule body and the amount of gas therein is so minimized.
  • the beverage powder may be compacted into a tablet during the Coffee Preparation Process 301 step, which is then positioned in the capsule body during the step of Product Filling & Densifying 302 .
  • each element of the operation is linked by a step for Transport 303 , where the capsule body is transferred between the devices for carrying out each element of the operation.
  • the elements for carrying out each of the elements of the process may be located in proximity to each other, or even integrated into each other, so that the time required for transporting the beverage capsule between elements is minimized. The process is thereby rendered more space-efficient and economical.
  • Membrane Attachment and Cutting 305 is attached to the flange of the capsule body at a plurality of regions of the flange, leaving a plurality of unsealed regions on said flange as well.
  • the membrane is also cut to a size which will cover the flange and open end of the capsule body.
  • Vacuum Application & Sealing 306 depicted in FIG. 1 , Views E-H.
  • a vacuum is applied to the capsule body, removing the gas from within through the plurality of unsealed regions of the flange.
  • the membrane is then sealed over the entirety of the surface of the flange, preserving the vacuum within the capsule.
  • the vacuum within the capsule is a reduction of pressure high enough to offset the pressure generated by the gases evolved by the coffee as it degasses in the capsule.
  • a normally configured beverage capsule will so resist the pressure accumulated within the sealed capsule as a result of the evolved gases.
  • the capsule is transferred to Distribution 308 , where it may be packaged in a box, sleeve, bag, or the like and distributed for sale.
  • the presently disclosed and/or claimed inventive concept(s) may be adapted to fabricate beverage capsules for the preparation of various kinds of alimentary substances, for example broth, cocoa, coffee, infant formula, milk, tea, tisane or any combination thereof.
  • the edible granules comprising said alimentary substances may be provided in various forms and sizes, such as flakes, grains, granules, pellets, powders, shreds, or any combination thereof. While the particular embodiment of the preceding description is directed to a beverage capsule containing a quantity of roasted, powdered coffee, it should not be construed as limiting the scope of the presently disclosed and/or claimed inventive concept(s) to beverage capsules so configured.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Apparatus For Making Beverages (AREA)
  • Vacuum Packaging (AREA)
  • Packages (AREA)
  • Closing Of Containers (AREA)
  • Package Closures (AREA)
US14/411,963 2012-07-04 2013-06-25 Method and Apparatus for Fabricating a Beverage Capsule Abandoned US20150225099A1 (en)

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EP12174912 2012-07-04
EP12174912.1 2012-07-04
PCT/EP2013/063174 WO2014005872A1 (en) 2012-07-04 2013-06-25 Method and apparatus for fabricating a beverage capsule

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US20140141128A1 (en) * 2012-11-12 2014-05-22 2266170 Ontario Inc. Beverage Capsule And Process And System For Making Same
US20160347483A1 (en) * 2014-02-06 2016-12-01 Gima S.P.A. Unit and method for releasing product for extraction or infusion beverages in containers forming single-use capsules or pods
US20170210498A1 (en) * 2016-01-25 2017-07-27 Kurt Allen Jenkins Method of Fabricating Coffee Pods at Point of Sale
US20180208335A1 (en) * 2015-07-24 2018-07-26 M.B. Societa' a Responsabilita' Limitata Apparatus for making a product, preferably a food product for making a drink by infusion in a respective liquid
US20180305116A1 (en) * 2015-10-30 2018-10-25 Cossa Polimeri S.R.L. Capsule for preparing infusion or soluble beverages
US10414529B1 (en) 2018-04-17 2019-09-17 William S. Bayer Machines and components for generating beverage pods for use in single serve beverage brewing machines
IT201900013185A1 (it) * 2019-07-29 2021-01-29 S A T S R L Apparato e metodo di chiusura di capsule
US11524268B2 (en) 2016-11-09 2022-12-13 Pepsico, Inc. Carbonated beverage makers, methods, and systems

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US10442610B2 (en) 2014-03-11 2019-10-15 Starbucks Corporation Pod-based restrictors and methods
ES2791960T3 (es) 2015-06-09 2020-11-06 K Fee System Gmbh Cápsula monodosis, sistema y procedimiento para la preparación de una bebida
AR105231A1 (es) * 2015-06-09 2017-09-20 Cryovac Inc Aparato y proceso para envasar productos
US11724873B2 (en) 2016-08-03 2023-08-15 Societe Des Produits Nestle S.A. Capsule for the preparation of a beverage containing pellets
DE102016120786A1 (de) * 2016-11-01 2018-05-03 Hauni Maschinenbau Gmbh Kapsel zum Einsetzen in einen Kopf einer Wasserpfeife, Maschine der Tabak verarbeitenden Industrie und Verfahren zum Herstellen einer solchen Kapsel
CN115867498A (zh) * 2020-07-15 2023-03-28 雀巢产品有限公司 制造用于储存单独的食品或饮料分份的包装条的方法以及因此获得的包装条
CN112758412A (zh) * 2020-12-22 2021-05-07 莆田市城厢区诚味食品有限公司 一种速冻肉全自动抽氧包装设备

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US20140141128A1 (en) * 2012-11-12 2014-05-22 2266170 Ontario Inc. Beverage Capsule And Process And System For Making Same
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IT201900013185A1 (it) * 2019-07-29 2021-01-29 S A T S R L Apparato e metodo di chiusura di capsule

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MX2014014954A (es) 2015-03-09
BR112014030477A2 (pt) 2017-06-27
EP2870069A1 (en) 2015-05-13
IN2014DN10126A (it) 2015-08-21
WO2014005872A1 (en) 2014-01-09
JP2015527261A (ja) 2015-09-17
RU2015103514A (ru) 2016-08-20
AU2013286097A1 (en) 2014-12-18
CN104395194A (zh) 2015-03-04
CN104395194B (zh) 2016-10-19
PT2870069T (pt) 2016-11-14
IL235872A0 (en) 2015-01-29
AR099245A1 (es) 2016-07-13
KR20150034235A (ko) 2015-04-02
CA2875326A1 (en) 2014-01-09
EP2870069B1 (en) 2016-08-31
ES2593352T3 (es) 2016-12-07

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