WO2025196014A1 - Compostable top lid structure for a beverage preparation capsule - Google Patents

Compostable top lid structure for a beverage preparation capsule

Info

Publication number
WO2025196014A1
WO2025196014A1 PCT/EP2025/057308 EP2025057308W WO2025196014A1 WO 2025196014 A1 WO2025196014 A1 WO 2025196014A1 EP 2025057308 W EP2025057308 W EP 2025057308W WO 2025196014 A1 WO2025196014 A1 WO 2025196014A1
Authority
WO
WIPO (PCT)
Prior art keywords
capsule
layer
beverage
chamber
delivery wall
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.)
Pending
Application number
PCT/EP2025/057308
Other languages
French (fr)
Inventor
Violette Catherine Marguerite Bourg
Chiara PAVAN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Societe des Produits Nestle SA
Nestle SA
Original Assignee
Societe des Produits Nestle SA
Nestle 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
Application filed by Societe des Produits Nestle SA, Nestle SA filed Critical Societe des Produits Nestle SA
Publication of WO2025196014A1 publication Critical patent/WO2025196014A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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

Definitions

  • the present invention relates to a capsule for preparing a beverage in a beverage production machine, to a system comprising the proposed capsule and to a use of the proposed capsule for preparing a beverage in a beverage production machine.
  • Single-serve beverage capsules for beverage preparation machines are known in the art. These capsules are commonly used for on demand dispensing of beverages, like coffee, tea or hot chocolate, and enjoy popularity due to their fresh tasting, variability of flavors and the convenience of the beverage preparation.
  • the capsule containing a beverage component is inserted in a capsule holder of a beverage preparation machine, the capsule holder is closed, and the beverage preparation is started.
  • Fluid such as water or milk
  • the capsule opens under pressure of the fluid to release the prepared beverage.
  • opening of the capsule can be accomplished by pressing an extraction face of the capsule with a force effected by increasing pressure of the fluid inside the capsule against an opening structure provided in the capsule holder such that the extraction face is torn upon reaching a breaking stress thereof.
  • the opening structure can be a number of relief and recessed elements, e.g., pyramid-like elements, onto which the extraction face extends and tears under the effect of the internal pressure of the fluid.
  • Such pressure-controlled beverage preparation has the advantage that it can produce a beverage of high quality.
  • the extraction face generally in the form of a delivery wall, needs to show a certain amount of stiffness to ensure pressure built-up in the capsule while avoiding collapse thereof during the opening process.
  • the extraction face should be configured such that it can be torn by the opening structure in the opening process.
  • particles and fibers from the beverage component are retained inside the capsule to avoid not only contamination of the prepared beverage but also obstruction of openings in the capsule and/or the opening structure that are provided for dispensing the prepared beverage out of the beverage preparation machine.
  • Aluminium offers a number of advantages, such as a high-pressure resistance, durability, flexibility, low weight, provision of long shelf-life and letting the taste of the prepared beverage unaltered.
  • some consumers are expecting capsules made of alternative material, and in particular capsules made of compostable material.
  • the capsule top lid membrane should: be fully biodegradable and/or compostable, have optimum barrier properties for an improved shelf life of the capsule ingredient, be tight sealed to the capsule rim with a high seal strength, sustain air freight and not detach or delaminate from the capsule body especially in tropical conditions, have a structure and related materials allowing the capsule to be opened by the opening structure of the beverage preparation machine during the capsule opening process, sustain the pressure inside de beverage extraction machine and not burst nor delaminate during extraction, and provide optimized extraction.
  • the term "machine” or “device” may refer to an electrically operated device or machine that: can prepare, from a precursor material or ingredient, a beverage and/or foodstuff, or; can prepare, from a pre-precursor material, a precursor material that can be subsequently prepared into a beverage and/or foodstuff.
  • the machine may implement said preparation by one or more of the following processes: dilution; heating; pressurization; cooling; mixing; whisking; dissolution; soaking; steeping; extraction; conditioning; infusion; grinding, and other like process.
  • the machine may be dimensioned for use on a work top, e.g. it may be less than 70 cm in length, width and height.
  • the term "prepare" in respect of a beverage and/or foodstuff may refer to the preparation of at least part of the beverage and/or foodstuff (e.g. a beverage is prepared by said machine in its entirety or part prepared to which the end-user may manually add extra fluid prior to consumption, including milk and/or water).
  • the beverage extraction device is a Nespresso Original Line extraction machine as described for example in one or more of EP0512468A1, EP0512470A1, EP1654966A1 or EP2142054A1.
  • the Nespresso® Original Line system when used with capsule made of aluminium are disclosed along with their opening system, for example, in one or more of EP0512468A1, EP0512470A1, EP1646305A1 or EP1165398A1.
  • constructional, manufacturing and/or (beverage) extraction details of such aluminium capsules and/or closing members are also disclosed.
  • the capsule is intended to be inserted into an extraction device, in which it can be pierced and injected with a fluid that passes through the bed of coffee contained in the capsule.
  • the capsule is then opened against a supporting part of the device comprising raised elements (in the form of truncated pyramids) under the effect of the pressure of the fluid entering and rising in the capsule.
  • the term "container” or "capsule” may refer to any configuration to contain the precursor material, e.g. as a single-serving, pre-portioned amount.
  • the container may have a maximum capacity such that it can only contain a single serving of precursor material.
  • the container may be single use, e.g. it is physically altered after a preparation process, which can include one or more of: perforation to supply fluid; for example a liquid like water, to the precursor material; perforation to supply the beverage/foodstuff from the container; opening by a user to extract the precursor material.
  • the container may be configured for operation with a container processing unit of the machine, e.g. it may include a flange for alignment and directing the container through or arrangement on said unit.
  • the container may include a rupturing portion, which is arranged to rupture when subject to a particular pressure to deliver the beverage/foodstuff.
  • the container may have a membrane for closing the container.
  • the container may have various forms, including one or more of: frustoconical; cylindrical; disk; hemispherical, and other like form.
  • the container may be formed from various materials, such as metal or plastic or wood pulp based a combination thereof.
  • the container is a compostable capsule, preferably made of cellulose and preferably made as a cellulose or wood pulp molded capsule. The material may be selected such that it is: food-safe; it can withstand the pressure and/or temperature of a preparation process.
  • the container may be defined as a capsule, wherein a capsule may have an internal volume of 20 - 100 ml.
  • the capsule includes a coffee capsule, e.g. a Nespresso® capsule (including a Classic/Original Line, Professional, or other capsule).
  • system or “beverage or foodstuff preparation system” may refer to the combination of any two or more of: the beverage or foodstuff preparation machine; the container; the server system, and the peripheral device.
  • the term "beverage” may refer to any substance capable of being processed to a potable substance, which may be chilled or hot.
  • the beverage may be one or more of: a solid; a liquid; a gel; a paste.
  • the beverage may include one or a combination of: tea; coffee; hot chocolate; milk; cordial; vitamin composition; herbal tea/infusion; infused/flavored water, and other substance.
  • the term "foodstuff” may refer to any substance capable of being processed to a nutriment for eating, which may be chilled or hot.
  • the foodstuff may be one or more of: a solid; a liquid; a gel; a paste.
  • the foodstuff may include yoghurt; mousse; parfait; soup; ice cream; sorbet; custard; smoothies; other substance.
  • a beverage can also be a foodstuff and thus a machine that is said to prepare a beverage or foodstuff does not preclude the preparation of both.
  • the beverage is coffee including roast and ground coffee.
  • the term "precursor material” or “ingredient” may refer to any material capable of being processed to form part or all of the beverage or foodstuff.
  • the precursor material can be one or more of a: powder; crystalline; liquid; gel; solid, and other.
  • a beverage forming precursor material include ground coffee; milk powder; tea leaves; coco powder; vitamin composition; herbs, e.g. for forming a herbal/infusion tea; a flavoring, and; other like material.
  • Examples of a foodstuff forming precursor material include dried vegetables or stock as anhydrous soup powder; powdered milk; flour-based powders including custard; powdered yoghurt or ice-cream, and; other like material.
  • a precursor material may also refer to any pre-precursor material capable of being processed to a precursor material as defined above, i.e. any precursor material that can subsequently be processed to a beverage and/or foodstuff.
  • the pre-precursor material includes coffee beans which can be ground and/or heated (e.g. roasted) to the precursor material.
  • the precursor material is roast and ground coffee.
  • fluid may include one or more of a liquid, for example, water; milk; other.
  • wood pulp-based may refer to the material or a portion of material forming the container which is one or more of: porous; fibrous; cellulosic; formed of cellulosic material; formed of natural cellulosic material; formed of reconstituted or regenerated cellulosic material; non-woven; is composed entirely of or is a composition of wood pulp, and is wet or dry formed.
  • a thickness of the wood-based material may be 0.25 mm to 0.75 mm or about 0.5 mm.
  • the wood-based material may be 200-400 gsm.
  • non-woven may refer to a fabric-like material which is not woven or knitted.
  • a non-woven material may be made from bonded together fibers.
  • porous may refer to material configured with interstices to transmit water (or other liquid) therethrough.
  • fibrous may refer to material comprised of fibers, which may be present in one or more of the material constituents.
  • cellulosic may refer to conventionally woody (from soft wood and/or hard wood species) and/or non- woody materials. These materials may be bleached and unbleached and may include a regenerated or reconstituted cellulose.
  • softwood are Pine, Spruce, Redwood etc.
  • hardwood are Maple, Oak, Ash, Eucalyptus, Maple, Birch, Walnut, Beech etc.
  • non-woody origin cellulose-based material are rice, manila hemp, sisal, jute, bamboo, maize, sugar cane, sugar cane residues (bagasse), banana peels, coffee ground.
  • natural cellulosic material may refer to conventionally woody materials or non-woody materials, which are not regenerated.
  • reconstituted or regenerated cellulosic material may refer natural cellulosic material subject to processing that comprises reconstitution or regeneration, examples include rayon and lyocell.
  • wood pulp may refer to a lignocellulosic fibrous material, which may be prepared by mechanical or chemical separation of cellulose fibers from one or more of wood, fiber crops, paper, or rags.
  • wet formed may refer to a process of forming from an aqueous solution of fibers. The aqueous solution of fibers may be heated and pressed in a mold to set the material and remove water therefrom.
  • dry formed may refer to a process of forming not using aqueous solution of fibers.
  • the capsule of the invention has the same design as a Nespresso® Original Line capsules and is fully made (capsule body and delivery wall) of compostable material, preferably of cellulose-based material, more preferably of pulp-molded cellulose-based material.
  • the capsule is in the form of a frustoconical cup and has for example a diameter of 2 - 5 cm and an axial length of 2 - 4 cm.
  • the capsule may have other crosssection shapes, including square, other polygons, or elliptical; the flange or rim portion is alternatively connected to the upper surface of the closing member, e.g. by crimping; the sidewall is alternatively arranged, including with the reverse taper or is aligned to the depth direction, or is curved; the base is alternatively arranged, including with as flat or curved; the flange or rim portion is connected to the storage portion rather than being integrally formed; the closing member is arranged as a storage portion, e.g. it comprises a cavity, and; the flange portion is omitted, e.g. the closing member connects directly to the storage portion.
  • the closing member is arranged as a storage portion, e.g. it comprises a cavity, and; the flange portion is omitted, e.g. the closing member connects directly to the storage portion.
  • a first aspect of the invention relates to a capsule for preparing a beverage in a beverage production machine.
  • the invention provides a capsule according to Claim 1.
  • the capsule may be understood as a receptacle or container for containing a substance for preparing a beverage and preferably may form a case or container that surrounds the substance.
  • the capsule body is of a three-dimension shape. It delimits with its sidewall (at least part of), a chamber, which may be a compartment, a cavity or a hollow space in the capsule, for example.
  • the chamber generally contains a beverage or foodstuff ingredient or substance for the preparation of the beverage.
  • the capsule body also comprises a rim portion delimiting an opening in the sidewall.
  • the capsule further comprises an injection wall closing the chamber at one end of the sidewall, and suitable for injecting a fluid in the chamber. Injection of the fluid may lead to an interaction of the fluid with the substance, which may include any kind of chemical and/or physical reaction between the substance and the fluid, such as wetting, infusion, extraction, dissolution, and/or any other kind of corresponding interaction to produce a beverage product.
  • the capsule further comprises a delivery wall that is connected to the capsule body to close the chamber.
  • a space inside the capsule may be (completely) surrounded from all sides by the container body (sidewall), the injection wall and the delivery wall, preferably such that the chamber for receiving the substance is formed (and closed).
  • a capsule can be provided that can be filled with a substance for preparing a beverage and used with known capsule machines.
  • the substance can be protected from degradation and outside influences, like oxidation or moisture, and flavors of the substance can be kept inside the capsule even when storing the same for extended periods.
  • the delivery wall of the invention is made of biodegradable materials and comprises in a layered manner and in this specific order (from the side facing away the capsule to the side facing the chamber of the capsule) a filter layer, a carrier layer, a barrier layer, a protective layer and a connecting layer for connection to the capsule body.
  • the delivery wall may comprise different parts that are arranged in plies, slats, tiers or as strata.
  • the delivery wall may have various (layer) configurations, forms and shapes.
  • the filter layer is provided for filtering out particles from the prepared beverage dispensed via the delivery wall.
  • the filter layer is positioned in the delivery wall as facing away from the chamber.
  • the filter layer is made of biodegradable and/or compostable material.
  • the carrier layer (also called retention layer) of the delivery wall is provided such that it may be opened upon pressure rinsing in the capsule and/or interaction with opening elements of a capsule holder (of a capsule chamber of the beverage production machine) under the effect of rising pressure of the fluid injected in the capsule, for example,) by relative movement between the respective elements.
  • the opening elements may have various configurations, forms and shapes and may comprise a plurality of relief and recessed elements, e.g. pyramid-like elements. This design allows tailoring the design of the delivery wall to technical needs.
  • the carrier layer is made of biodegradable and/or compostable material.
  • each of the filter layer and the carrier layer is made of a biodegradable, preferably compostable material. This may lead to a more straightforward recovery of the organic material inside the capsule as well as of the capsule material itself.
  • the barrier layer is also made of biodegradable material. It provides a preferably bidirectional barrier against moisture and/or gas, the barrier layer is preferably made of a different material than the filter layer and/or the carrier layer; the barrier layer being applied on the surface of the carrier layer facing the chamber.
  • the barrier properties are preferably against moisture and/or liquid and/or gaseous substance, preferably oxygen, entering and/or leaving the chamber.
  • the barrier layer is preferably made of a different material than the filter layer and/or the carrier layer as the expected physicochemical properties of the barrier layer are protection of the substance enclosed in chamber against moisture and/or oxygen and not any filtering or retention properties.
  • each of the filter layer, the barrier layer and the carrier layer is made of a different biodegradable and preferably compostable material, wherein preferably the different materials distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation.
  • biodegradable material may be understood as any material that can be broken down into environmentally innocuous products by (the action of) living things (such as microorganisms, e.g. bacteria, fungi or algae). This process could take place in an environment with the presence of oxygen (aerobic) and/or otherwise without presence of oxygen (anaerobic). This may be understood, for example, as meaning that composting can be carried out without reservation. In particular, at the end of a composting process there are no residues of the material, which may be problematic for the environment, or any non-biodegradable components.
  • biodegradable materials for the carrier layer or the filter layer may be different plant-based materials, such as wood, bamboo, bamboo fibres, cellulose, cellulose pulp, wood pulp, sugarcane pulp, paper and/or cardboard.
  • bioplastic families such as biopolymers such as polyhydroxybutyrate (PHB) and co-polymers, polybutylene succinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A/PBSa), polylactide (PLA), polybutylene adipate terephthalate (PBAT), Cellulose Acetate, starch and/or compounds or combination of above mentioned materials are other examples.
  • the delivery wall further comprises at least one protective layer and a connecting layer.
  • the protective layer is applied on the side of the barrier layer facing the capsule's chamber for protecting the barrier layer at least against moisture.
  • the connecting layer is applied on the protective layer and forms the external layer of the delivery wall facing the chamber. It allows connection of the delivery wall to the rim portion of the capsule body.
  • the connecting layer is made of biodegradable material thereby participating in the biodegradability of the full structure.
  • the connecting layer comprises at least a non-woven aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co-adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof.
  • PVA Polylactic acid
  • PBS Polyhydroxy alkanoate
  • PBS Polybutylene succinate
  • PBSA Polybutylene succinate-co-adipate
  • PBAT Polybutylene adipate-co-terephthalate
  • PBSeT Polybutylene sebacate-co-terephthalate
  • the proposed structure has the advantage of providing an increased amount of material for connection to the rim portion of the capsule body to improve the sealing of the delivery wall onto the capsule body while, thanks to the use of a non-woven material, managing the total thickness of the delivery wall to allow for its opening during extraction of the capsule in the beverage preparation machine.
  • the proposed materials for the connecting layer are not defined as having adhesive properties. However, they provide, upon (sealing) connection onto the rim portion of the capsule body, a high and efficient connection of the delivery wall on the capsule body.
  • the connecting layer has a grammage comprised between 30 and 180 g/m 2 , preferably between 35 and 120 g/m 2 .
  • the quantity of material of the proposed connecting layer is important when compared to the usual quantity of material used when the connection of the delivery wall and the capsule body is made using a heat-seal lacquer or a heat-sealable coating - generally between 10 and 20 g/m 2 to provide sealing on the capsule and still allow for opening of the delivery membrane during extraction.
  • the connecting layer of the delivery wall is sealed, preferably by heat-sealing or ultrasonic sealing, to the rim portion of the capsule body.
  • the use of sealing technology combined with the higher quantity of material available for the sealing allows the seal strength between the delivery wall and the capsule body to be improved. With the proposed material for the connecting layer and sealing technology, the connection between these two elements resists to air freight and tropical conditions.
  • the capsule body and preferably the injection wall comprise a barrier layered and/or laminated, protective film extending onto the rim portion of the capsule body onto which the connecting layer of the delivery wall is sealed.
  • the protective film may be in the form of a liner structure or in a form of a coating (applied in one or more layers).
  • a protective film (also called liner) in the form of a multilayer biodegradable structure comprising polymers may be used. An example of which is disclosed in WO 2021/145764
  • the connecting layer and the protective film are then sealed together, and their respective material locally melted and mixed to provide high strength connection.
  • the sealing strength of the delivery wall on the rim portion of the capsule body comprising the protective film is at least 6 N/15 mm measured according to ASTM F88/F88M-21 related to Standard Test Method for Seal Strength of Flexible Barrier Materials.
  • the sealing strength between the delivery wall and the capsule body is improved over the compostable cellulose based capsule solutions using heat-seal lacquer for delivery wall/cup body connection, currently available on the market.
  • the sealing of the connecting layer to the rim portion is limited to a peripheral portion of the connecting layer.
  • two regions can be defined on the connecting layer: a first region at the periphery of the connecting layer and corresponding to the portion that is sealed to the protective film laminated or thermoformed on the capsule body having an improved connection with the capsule body, and a second region corresponding to the non-sealed portion of the connecting layer which thanks to the non-woven structure of the material, allows for opening of the delivery wall despite to thickness of the connecting layer.
  • the proposed delivery wall structure integrating a non-woven connecting layer combines an improved sealing strength between the delivery wall and the capsule body with a higher thickness of the connecting layer while enabling optimized opening of the delivery wall despite the thickness of the connecting layer.
  • the connecting layer be obtained by spun bond, melt blown or stapple fibers process and applied on the delivery wall by lamination during the production process of the delivery wall. This allows for controlled production and precise application on the delivery wall.
  • the connecting layer is obtained using a spun bond production process which allows to have a non-woven structure of controlled material density and thickness.
  • the delivery wall further comprises at least one adhesive layer positioned between the protective layer and the connecting layer to ensure optimized bonding of the connecting layer onto the protective layer.
  • the adhesive layer helps protecting the barrier layer during lamination of the connecting layer on the delivery wall structure.
  • the adhesive layer is proposed to be biodegradable similarly as the other layers of the delivery wall. It may in particular comprise material such as a vegetable-based starch or acrylic adhesive polymers.
  • the filter layer is made of a compostable and non-woven material, preferably cellulose fiber such as wood or non-wood fibers or sugarcane pulp.
  • Alternative material may be rayon fibers, aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co-adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof.
  • PVA Polylactic acid
  • PBS Polyhydroxy alkanoate
  • PBS Polybutylene succinate
  • PBSA Polybutylene succinate-co-adipate
  • PBAT Polybutylene adipate-co-terephthalate
  • PBSeT Polybutylene sebacate-co-terephthalate
  • the filter layer has a grammage between 10 and 150 g/m 2 , preferably between 20 and 100 g/m 2 .
  • a filter layer with a grammage between 10 and 150 g/m 2 preferably between 20 and 100 g/m 2 allows ensuring efficient filtering of any particle of the substance enclosed in the capsule chamber, for example roast and ground coffee.
  • the characteristics of the filter layer can be set by defining its area density of material, i.e. as mass per unit of area.
  • the tensile strength of the filter layer can be improved by increasing the grammage of its material and/or by using a (non-woven) material comprising fibers of a defined length and/or with a defined fiber bonding.
  • the filtration capacity and/or the porosity of the filter layer can be modified, e.g. reduced to smaller particle diameters, by setting the filter layer's material characteristics accordingly. Thereby, it is possible to tailor the filter layer to the specific requirements of the beverage preparation.
  • the carrier layer is made of a material that is biodegradable and compostable and has a defined closed fiber structure with at least 50% of weight comprising paper, softwood, hard wood or non-woody material and combination thereof.
  • the carrier layer is made of paper-based material.
  • the carrier layer When the carrier layer is cellulose based, it may have a grammage comprised between 20 and 150 g/m 2 , preferably between 30 and 100 g/m 2 .
  • the closed fiber structure corresponds to Polyhydroxy alkanoate (PHA), Polyhydroxy butyrate (PHB) and co-polymers, Polybutylene succinate (PBS/PBS-A), biopolyesters, Cellulose Acetate, starch, polyvinyl alcohol (PVOH), polymers or co-polymers where at least one of the monomer units is vinyl alcohol, compounds and/or laminates of the above-mentioned materials.
  • PHA Polyhydroxy alkanoate
  • PB Polyhydroxy butyrate
  • PBS/PBS-A Polybutylene succinate
  • biopolyesters Cellulose Acetate
  • starch starch
  • PVOH polyvinyl alcohol
  • polymers or co-polymers where at least one of the monomer units is vinyl alcohol, compounds and/or laminates of the above-mentioned materials.
  • the carrier layer preferably the material of the carrier layer, is configured such that it is resilient against a built-up pressure in the chamber between 1 and 20 bar, more preferred between 10 and 20 bar, most preferred between 12 and 18 bar.
  • the characteristics of the carrier layer can be adjusted.
  • the tensile strength of the carrier layer can be improved by increasing the grammage of its material.
  • the filter layer is provided opposite to the chamber with respect to the carrier layer.
  • This particular order and orientation of the carrier layer and the filter layer with respect to the capsule body leads to a number of improvements. For example, it is observed that the pressure profile during the beverage preparation is more consistent and reproducible. Moreover, a better crema formation and extraction and a reduced concentration of particles and residues of the substance, e.g. roast and ground of coffee, is found with this configuration in the beverage.
  • the carrier layer may face the chamber or may be provided closer to the chamber than the filter layer.
  • the expression "facing" may be understood as being directed towards the respective reference object without necessarily having to be provided directly onto the respective reference object.
  • the delivery wall also comprises a barrier layer.
  • the barrier layer provides a, preferably bidirectional, barrier against moisture and/or oxygen and is made of a biodegradable, preferably compostable, material, such as biopolymers, Polyglycolic acid (PGA), Polyvinyl alcohol (PVOH), Butanediol vinyl alcohol co-polymer (BVOH) or any vinyl alcohol co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above-mentioned materials.
  • PGA Polyglycolic acid
  • PVOH Polyvinyl alcohol
  • BVOH Butanediol vinyl alcohol co-polymer
  • any vinyl alcohol co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above-mentioned materials.
  • the barrier layer is made of a different material than the filter layer and/or the carrier layer. This allows benefiting from the different material properties of both the filter layer and the carrier layer.
  • the barrier layer is applied in one or more layers in a total quantity of 2 to 50 gsm (g/m 2 ), preferably of 5 to 40 gsm (g/m 2 ).
  • the proposed total barrier layer quantity allows to have sufficient barrier material to provide a barrier effect.
  • the barrier layer is applied on the surface of the carrier layer facing the chamber.
  • the surface of the carrier layer on which the barrier layer is applied has preferably a surface roughness lower than 1,3 microns when measured according to ISO 3274.
  • Oxygen transmission rate is the measurement of the amount of oxygen gas that passes through a substance over a given period. It is mostly carried out on non-porous materials, where the mode of transport is diffusion. In the present case, it relates to the permeation of oxygen through a packaging material (delivery wall) to sensitive foods like coffee. OTR measurement methodology uses ASTM D3985/ISO 15105 with typical measured Test Area of 50cm2 with Analysis conditions: 23°C and 50% Relative Humidity.
  • Roughness is a component of surface texture. It is quantified by the deviations in the direction of the normal vector of a real surface from its ideal form.
  • Roughness measurement may use surface profile measurement using a profilometer. In the present case it is done using a contact or stylus profilometers (such as Smithers' portable Handysurf E-35B) which moves a loaded diamond probe across the surface and record the vertical movement of the stylus caused by the surface irregularities. Samples have been measured 15 times. Controlling the roughness of the carrier layer surface before applying the barrier layer ensures regular application of the barrier layer on a material surface having more closed pores thereby improving the barrier layer properties, especially in OTR performances.
  • the Oxygen Transmission Rate (OTR) of the delivery wall (300) is below 35 cc/m 2 /day, preferably below 10 cc/m 2 /day, most preferably below 1 cc/m 2 /day, measured according to ASTM D3985/ISO 15105 methodology.
  • the controlled surface roughness coupled to the total quantity of barrier material applied on the carrier layer allows for improved OTR performances of the delivery wall via a decrease in the OTR values. Hence a tighter capsule may be obtained.
  • the one or more protective layer is applied directly on the surface of the barrier layer facing the chamber of the capsule.
  • the protective layer is applied in one or more protective layers in a total amount of 5 to 30 gsm (g/m 2 ), preferably between 5 and 20 gsm (g/m 2 ) and with a maximum total thickness of 20 microns.
  • the protection of the barrier layer is ensured, and it is thereby possible to guarantee that the barrier layer is fully protected during the lamination of the further layers on the delivery wall and from moisture (to which the barrier layer is generally sensitive).
  • the protective layer is made of a biodegradable and preferably compostable material, such as vegetable starch-based, protein-based, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof.
  • a biodegradable and preferably compostable material such as vegetable starch-based, protein-based, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof.
  • the protective layer is preferably non hydrosoluble to avoid its degradation by the moisture content of the substance enclosed in the chamber.
  • the protective layer is also preferably made of a different material than the filter layer and/or the carrier layer to ensure proper separation of the physicochemical properties of the different layers.
  • the controlled surface roughness, the defined total quantity of barrier material applied on the carrier layer coupled with the application of a protective layer in one or more layers allows for further improved OTR performances of the delivery wall.
  • the proposed delivery wall with improved OTR performances and sealing strength properties participate in increasing the protection of the substance filled in the capsule chamber, generally roast and ground coffee, thereby increasing the shelf-life of the capsule itself for the benefit of the consumer.
  • the delivery wall also comprises a bonding layer which allows to, at least partially, join the filter layer and the carrier layer to each other on opposite sides thereof, preferably through adhesive bonding or heat-sealing.
  • the bonding layer is provided between the carrier layer and the filter layer to ensure efficient adhesion of the two above-mentioned layers.
  • the bonding layer is of a biodegradable and preferably compostable material, such as vegetable based starch or acrylic adhesive and participate to the biodegradable properties of the complete capsule.
  • the different layers forming the delivery wall namely, the filter layer, the bonding layer, the carrier layer, the barrier layer, the protective layer, the adhesive layer and the connecting layer, which can be each formed of one or more layers, are made of different biodegradable, preferably compostable, material.
  • the delivery wall may comprise additional layers beside the filter layer, the carrier layer, and the adhesive layer. These additional layers may be intercalated between the filter layer, carrier and the adhesive layers as needed and depending on their function.
  • the different layers are preferably made of different materials that preferably distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation.
  • the delivery wall may comprise multiple different layers, which preferably may be made from different materials. This may lead to the advantageous effect that the combination of the two or more constituent materials with different physical or chemical properties produce a structure with characteristics different from each of the individual components. Thereby, the interface of the capsule to the outside can be tailored to the technical needs of the application.
  • the pressure built up inside the capsule can be controlled and defined as required.
  • the capsule can be designed to produce a beverage according to the specifications of its recipe.
  • material characteristics relevant for the interaction of the delivery wall with the prepared beverage such as defining the filtering capabilities of the delivery wall.
  • the difference of orientation of the individual layers of the delivery wall may lead to different stresses in the layers, which can be taken into consideration with the above configuration by selecting different materials.
  • the material of one of the layers may break at a lower pressure than the material of another layer but the structure may be kept together by the combined resistance of each material, which may support each other under the effect of pressure.
  • one or more of the different layers of the delivery wall namely the filter layer, the bonding layer, the carrier layer, the barrier layer, the protective layer, the adhesive layer and the connecting layer, is laminated with the other layers of the delivery wall. Thanks to the lamination of one or more of the mentioned layers, it is possible to produce a blank foil that is cut or punched to form the delivery wall. Depending on the dimension of the blank, several delivery walls may be formed from the same blank.
  • the proposed capsule body and preferably the injection wall is preferably made of molded pulp fiber and comprises a layered and/or laminated, protective film.
  • the capsule body and the injection wall are made up of separate pieces or are integrally formed, e.g., as a one-piece. This opens different manufacturing options for the capsule body and/or injection wall.
  • a further aspect of the present invention relates to a system for preparing a beverage comprising a capsule containing a beverage ingredient, preferably roast and ground coffee and as above described and a beverage production machine.
  • the proposed system makes use of a beverage production machine with a fluid dispensing device capable of feeding the capsule with an amount of a fluid, such as water, with a pressure between 2 bars and 20 bars at a first end of the capsule formed by the injection wall, and with a brewing chamber, comprising a first part for hosting the capsule and a second part for closing the brewing chamber.
  • the second part of the brewing chamber comprises a capsule holder that comprises an opening structure (with opening elements) for engaging with the delivery wall of the capsule at the second end of the sidewall when the brewing chamber holding the capsule is closed.
  • the opening structure comprises a relief and recessed surface facing, in use, the delivery wall, preferably the filter layer of the capsule.
  • the delivery wall when in use in the closed brewing chamber is opened with reduced tearing by the relief and recessed surface of the opening structure, when compared with a capsule comprising an aluminium delivery wall.
  • An additional aspect of the present invention relates to a use of a capsule as described above for preparing a beverage in a beverage production machine having a capsule holder. So, a beverage can be prepared in an advantageous and ecologically beneficial manner.
  • Figure 1 shows a schematic exploded view of a capsule according to an embodiment of the invention.
  • Figure 2 shows an enlarged schematic cross-section of a section of the delivery wall of the capsule of Figure 1 showing the different layers of the delivery wall.
  • Figure 3 shows a detailed view of another embodiment of a capsule of the invention integrating the delivery wall of Figure 2.
  • FIGS. 1 and 3 show different views, and aspects and features of a capsule 100 and related components of the present invention for preparing a beverage in a beverage production machine in accordance with the present invention.
  • Figures 1 shows an exploded view of a schematic capsule according to an embodiment of the present invention whereas
  • Figure 3 shows a detailed design of another embodiment of the capsule of the invention, and
  • Figure 2 shows in schematic cross-section the detailed layer structure of the delivery wall of the capsule of the proposed invention.
  • the capsule 100 may have a composite structure and/or may be made from a composite material, which preferably may consist entirely of biodegradable and/or compostable materials.
  • the capsule 100 comprises a capsule body 200 with a three-dimensional shape with a sidewall 210.
  • the capsule body 200 may have any shape or form, for example the capsule body may be in the form of a cup-shaped body.
  • the capsule body 200 may have a form that is suitable for the capsule 100 being inserted in a capsule holder of a (known) beverage production machine, for example a Nespresso® beverage production machine.
  • the capsule body 200 may have a frustoconical, truncated-, cup- or bowl-shaped form.
  • the capsule body 200 may have a circular cross-section. Thereby, for example, pressure related forces exerting on the capsule body 200 can be absorbed.
  • the capsule body 200 comprises a sidewall 210.
  • the sidewall 210 delimits a chamber 250 inside the capsule 100.
  • the sidewall 210 may be provided such that it encloses a continuous space inside the capsule body 100. This is shown exemplarily in Figure 1.
  • the chamber 250 is arranged to receive and store a substance 500 for the preparation of the beverage.
  • the substance 500 may be any type of (solid, liquid, at least partially soluble and/or percolate-able) matter of a particular or definite chemical constitution.
  • substances 500 may be roasted ground coffee, instant coffee, tealeaves, syrup concentrate, fruit extract concentrate, a chocolate product, dehydrated edible substances, and/or combinations thereof depending on the extraction process taking place.
  • examples for beverages that may be prepared may be coffee- or chocolate-based drinks, or other similar types of food.
  • the above examples for the substance 500 and beverages are not to be seen as a complete enumeration. Instead, various other examples are conceivable.
  • the capsule body 200 may have an opening 230 to the chamber 250.
  • the opening 230 may be on at least one of the capsule body's 200 opposite ends.
  • the substance 500 may be filled inside the capsule 100 through the opening 230.
  • the substance 500 may fill the chamber 250 entirely.
  • a rim portion 211 of the sidewall 210 may delimit the opening 230.
  • the rim portion 211 may have the form of a flange and extend from the sidewall 210, preferably away from the chamber 250.
  • the capsule 100 may be placed on the rim portion 211 inside a capsule holder of a beverage production machine.
  • the sidewall 210 may be provided such that it forms a continuous mantle surface of the capsule body 200.
  • the sidewall 210 may have an inside surface facing the chamber 250 and an outside surface facing away from the chamber 250.
  • a protective film 400 for providing a preferably bidirectional barrier against moisture and/or oxygen for the substance 500 may be provided on the capsule body 200 and/or the sidewall 210.
  • the protective film 400 is exemplarily illustrated as being provided as a liner on the inside surface of the sidewall 210, which may extend up to and over the rim portion 211.
  • the protective film 400 may be provided additionally or alternatively on the outside surface of the sidewall 210. Additionally, or alternatively, the protective film may be provided as a coating having similar barrier properties.
  • the protective film 400 may be made of a biodegradable and preferably compostable material, such as biopolymers or bioplastic families such as PHA and co-polymers (including PHB), PBS, PBS-A, PLA, PBAT, Cellulose Acetate, starch, PGA, PVOH, and it may include any polymers or co-polymers where at least one of the monomer units is vinyl alcohol (for example BVOH, Butenediol vinyl alcohol), as well as compounds or laminates of any of the above-mentioned materials.
  • the protective film 400 may be made of a food safe material (FCS, FCMs).
  • the capsule body 200 may be made of (wet/dry) molded pulp fiber.
  • the capsule body 200 may be made of a biodegradable and/or compostable material.
  • the capsule body 200 may be made of a food safe material (FCS, FCMs).
  • FCS food safe material
  • FCMs food safe material
  • the capsule body 200 may comprise a layered and/or laminated structure.
  • the capsule body 200 may be relatively stiff or rigid so not to collapse during operation in a beverage production machine or during storage.
  • the layered and/or laminated design may provide the capsule body 200 with additional rigidity and/or stiffness in comparison to other designs.
  • the molded pulp fiber may be a composite having an additional substrate, such as biodegradable resin, laminated on the capsule body 200.
  • a laminated structure of the capsule body 200 may be created by providing the protective film 400 thereon.
  • the capsule body 200 may comprise, for example, in addition to the protective film 400 a further laminate film or layer.
  • the capsule body 200 may be made of paper-based material or of a paper-based material with a laminate, specifically shaped to delimit a chamber 250.
  • the capsule body 200 is made of cellulose base pulp molded material, preferably woold pulp material using a wet pulp molding process.
  • the capsule 100 comprises an injection wall 220 for injecting a fluid in the chamber 250 for preparing the beverage upon interaction of the fluid with the substance 500. This is exemplarily illustrated in Figure 1.
  • the injection wall 220 may be provided on an opposite end of the capsule body 200 to the opening 230.
  • the injection wall 220 may be provided integrally or separately with the capsule body 200.
  • the capsule body 200 and the injection wall 220 may be made up of separate pieces or may be integrally formed as a one-piece.
  • the injection wall 220 may form a tapered end portion of the capsule body 200.
  • the injection wall 220 may be configured to be perforated by blades of the coffee production machine such that the blades provide openings for the fluid injection.
  • the fluid may be a liquid or a liq uid/gas mixture, such as water or milk.
  • the injection wall 220 may comprise also the above-described protective film 400.
  • the injection wall 220 may comprise (small) openings through which blades of the coffee production machine can enter and pierce the protective film 400.
  • the injection wall 220 may comprise a layered and/or laminated structure and may be made of (laminated) molded pulp fiber and/or a food safe material (FCS, FCMs).
  • the capsule body 200 and the injection wall 220 may be provided such that the chamber 250 is closed (sealed) preferably from at least three sides as shown in Figure 1.
  • the capsule body 200 and the injection wall 220 may be provided such that the injected fluid is dispersed evenly in the chamber 250 along the sidewall 210.
  • FIG. 3 An alternative and detailed capsule body 200 is proposed in Figure 3 in which, in addition to the integral injection wall 220 and rim portion 211, the capsule comprises a tapered sidewall 210, a stacking rim 280 and a base portion 260 comprising stiffening ribs 270 and the injection wall 220.
  • the capsule body 200 is disclosed in detail, for example, in WO2023/051967 Al and WO2023/052352 Al, the content of which is incorporated by reference.
  • the capsule body 200 of Figure 3 is closed by a delivery wall (not presented in the figure) similar to the one disclosed in connection with Figure 1 and Figure 2.
  • the capsule 100 comprises a delivery wall 300, which is connected to the capsule body 200 to close the chamber 250. This is exemplarily indicated in Figure 1 and in Figure 2.
  • the delivery wall 300 is provided in a layered manner as exemplarily shown in Figure 1. There is no limitation on the number of (different) layers the delivery wall 300 may have. In Figure 1, only the main layers of the delivery wall are presented while in Figure 2 additional layers are added for connecting purpose between the main layers.
  • the delivery wall 300 is flat.
  • the word "flat” shall mean that the delivery wall 300 extends substantially in one plane. In other words, the delivery wall 300 extends in one plane, but it can be deformed in a convex or concave plane, depending on the relative pressure between the inside and the outside of the capsule. In particular, it can happen that the ingredient contained therein (e.g., roast and ground coffee) will produce gases such as carbon dioxide over the storage period of the pod. In this case, an overpressure can be created within the capsule, which forces the - initially flat - delivery wall to bulge outside.
  • the ingredient contained therein e.g., roast and ground coffee
  • the atmospheric pressure varies around the capsule, for instance if the capsule is formed, filled and sealed at a factory which is near sea level, and then said capsule is transported at a higher altitude, where the atmospheric pressure is lower. In such case, the - initially flat - delivery will deflect inwardly in a concave shape.
  • the delivery wall comprises: o a filter layer 310 for filtering out particles from the prepared beverage dispensed via the delivery wall, o a carrier layer 320 being adapted to be opened under the effect of rising pressure of the fluid being injected into the capsule, o a barrier layer 340 for providing a preferably bidirectional barrier against moisture and/or gas and applied on the surface of the carrier layer 320 facing the chamber 250 of the capsule body 200, o a protective layer 350 applied on the side of the barrier layer facing the chamber 250 for protecting the barrier layer 340 at least against moisture, and o a connecting layer 330 applied as an external layer on the side of the delivery wall 300 facing the chamber 250 for connection of the delivery wall 300 to the rim portion 211 of the capsule body 200.
  • the delivery wall 300 is intended to be connected to the protective film 400 applied (by lamination / thermoforming) on the inner walls of the chamber 250 and on the rim portion 211 of the capsule body.
  • the delivery wall 300 is sealed to the protective film 400 at the location of the rim portion 211.
  • the filter layer 310, the carrier layer 320 the barrier layer 340, the protective layer 350 and the connecting layer 330 are all made of biodegradable, preferably compostable, material and are presently made of different material.
  • the filter layer 310 may be configured to filter out particles from the prepared beverage before dispensing the same via (from) the delivery wall 300.
  • the filter layer 310 may be a film, membrane or ply of a defined thickness (and/or with a (largely) planar surface).
  • the filter layer 310 is made of biodegradable material.
  • the filter layer 310 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also.
  • FCS food safe material
  • the filter layer 310 is made of a non-woven material, such as cellulose fibers from wood pulp (soft or hard wood material), or from non-woody material like sugarcane, bamboo, or hemp.
  • cellulose fibers from wood pulp (soft or hard wood material), or from non-woody material like sugarcane, bamboo, or hemp.
  • Alternative material like PLA, rayon fibers, PBS, PBS-A, PHB, PBAT, PBSeT, their respective copolymers and combination thereof may also be selected.
  • the mechanical and filtering properties of the filter layer 310 may be influenced by the thickness of the material, its density as well as its permeability for particles.
  • the filter layer 310 may have a thickness of material of 10 to 300 micrometers, preferably 20 to 250 micrometers. Additionally, or alternatively, the filter layer 310 may have a grammage between 10 and 150 gm (g/m 2 ), preferably between 20 and 100 gsm (g/m 2 ).
  • the carrier layer 320 is adapted to be opened under the effect of rising pressure of the fluid being injected in the capsule 100 during extraction in the beverage preparation machine.
  • the carrier layer 320 may be a film, membrane or ply with a defined thickness and preferably with a substantially planar surface.
  • the carrier layer 320 is also made of biodegradable material.
  • the carrier layer 320 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also.
  • the (material of the) carrier layer 320 has a defined fiber structure, such as a closed fiber structure.
  • the carrier layer 320 material may be a fiber structure with at least 50% of weight corresponding to cellulose fibers, comprising paper, softwood, hardwood, or non-woody material.
  • the carrier layer 320 may be provided such that it is resilient against a built-up pressure in the chamber 250, preferably between 1 and 20 bar, more preferred between 10 and 20 bar, most preferred between 12 and 18 bar.
  • the material of the carrier layer 320 may be configured such that it is resilient against a built-up pressure in the chamber 250 within such pressure ranges. Therein, the thickness and density of the material may influence the stiffness, i.e., the resistance to a bend, of the carrier layer 320.
  • the carrier layer 320 may have a thickness of material of 0 to 150 micrometers, preferably 30 to 70 micrometers. Alternatively, or additionally, the carrier layer 320 may have a grammage between 20 and 150 g/m 2 , preferably between 40 and 100 g/m 2 .
  • the delivery wall 300 also comprises a barrier layer 340 which provides a barrier against moisture and/or oxygen.
  • the barrier is chosen to be a bidirectional barrier against moisture and oxygen to preserve the substance 500, preferably roast and ground coffee, from the moisture and oxygen present outside the capsule.
  • the bidirectional barrier layer 340 acts against liquid and/or gaseous substances/contents entering or leaving the chamber 250. With such an arrangement, the substance 500 keeps its initial quality and does not alter over time.
  • the barrier layer 340 is positioned on the side of the carrier layer 320 facing the capsule opening 230. It is indeed positioned closest to the opening 230 of the capsule so as to allow keeping all the nutritional properties and aromas of the substance 500.
  • the barrier layer 340 may be provided in the form of a single layer or in the form of multiple layers and its total thickness may vary between 1 micrometer and 10 micrometers.
  • the amount of barrier material in one barrier layer 340 may be comprised between 0,1 to 10 gsm (g/m 2 ) for a total quantity in the total number of barrier layers 340 of 2 to 50 gsm, preferably of 5 to 40 gsm.
  • PGA Polyglycolic acid
  • PVOH polyvinyl alcohol
  • BVOH butanediol vinyl alcohol co-polymer
  • the barrier layer 340 is made of BVOH (Butanediol vinyl alcohol co-polymer) or co-polymer.
  • the barrier layer is applied in several layers and has a total thickness between 3 and 4 micrometers.
  • the total thickness of the barrier layer should not exceed 10 micrometers and 50 gsm as it would bring the risk of non-piercing or bad-piercing of the delivery wall during extraction of the capsule.
  • the barrier layer 340 is directly applied on the surface of the carrier layer 320 that is facing the capsule chamber 250 when the delivery wall 300 is sealed onto the capsule body 200.
  • the associated Oxygen Transmission Rate (OTR) (measured in cc/m 2 /day) of the delivery wall 300 presented in Figure 1 and 2 is measured as being below 10 cc/m 2 /day and in some cases depending on the material selection for the different layers, below 1 cc/m 2 /day.
  • the surface of the carrier layer 320 onto which the barrier layer 340 is applied may be controlled / treated to have a reduced surface roughness with the aim of further improving the OTR.
  • the delivery wall 300 also comprises at least one protective layer 350 applied on the side of the barrier layer 340 facing towards the chamber 250.
  • the protective layer 350 is applied directly on the barrier layer 340 and aims at protecting the barrier layer 340 against moisture and/or oxygen to ensure optimized oxygen barrier performance of the barrier layer.
  • the protective layer 350 also protects the barrier layer 340 during the lamination of the subsequent layers (connecting layer for example) during the production of the delivery wall 300.
  • the protective layer 350 is preferably applied in several layers so as to enhance the protecting effect of the protective layer for the barrier layer 340.
  • the protective layer 350 is made of a biodegradable and preferably compostable material and participate to the full biodegradability of the delivery wall 300.
  • the protective layer 350 may be made from a material that is preferably non-hydrosoluble, such as vegetable starch-based, proteinbased, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof.
  • a material that is preferably non-hydrosoluble such as vegetable starch-based, proteinbased, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof.
  • Commercially availableproducts from different companies like BASF, Henkel or Sun Chemicals may be used.
  • the total amount of material for protective layer is comprised between 5 and 30 gsm (g/m 2 ), preferably between 5 and 20 gsm (g/m 2 ).
  • the selected material and amount of material allows limiting the thickness of the protective layer 350 to a maximum total thickness of 20 microns. indeed, the quantity of material thickness of the protective layer (applied in one or more layers) should not respectively exceed 40 to 50 gsm and 30 microns the due to possible issue on piercing of the delivery wall during extraction.
  • the delivery wall 300 comprises a connecting layer 330 to connect the delivery wall 300 to the rim portion 211 of the capsule body 200 to close the chamber 250, thereby forming a closed capsule 100.
  • the connecting layer 330 is hence applied as the external layer on the side of the delivery wall 300 facing the chamber 250 for connection of the delivery wall 300 to the rim portion 211.
  • the connecting layer 330 is connected to the rim portion 211 of the capsule body comprising the protective film 400.
  • the protective film 400 and the connecting layer 330 are then bonded together to ensure tight closure of the capsule 100.
  • the material of the connecting layer 330 is selected to be biodegradable and preferably compostable and is selected material to be non-hydrosoluble to avoid any interaction with / degradation by the moisture content of the beverage substance 500 which may be, for example, roast and ground coffee, contained in the chamber 250.
  • the material of the connecting layer 330 be selected to comprise a non-woven aliphatic or aliphatic aromatic polyester or a combination thereof.
  • the non-woven material may be selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co- adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co- terephthalate (PBSeT), and their respective copolymers, and combination thereof.
  • PHA Polylactic acid
  • PBS Polyhydroxy alkanoate
  • PBS Polybutylene succinate
  • PBSA Polybutylene succinate-co- adipate
  • PBAT Polybutylene adipate-co-terephthalate
  • PBSeT Polybutylene sebacate-co- terephthalate
  • non-woven structure of the connecting layer 300 it is possible to have a grammage of the material of the connecting layer comprises between 25 and 150 g/m 2 , preferably between 35 and 100 g/m 2 with limited impact on the delivery wall opening and on the extraction during the extraction of the capsule.
  • the connecting layer 330 may be obtained by spun bond, melt blown or stapple fibers process. However, additional production process leading to non-woven structure may be considered.
  • the connecting layer is applied on the delivery wall 300 by lamination during the production of the delivery wall 300.
  • the connecting layer 330 is sealed, preferably by heat-sealing or ultrasonic sealing, or connected by adhesive connection, to protective film 400 at the location of the rim portion 211 of the capsule body 200 to form the final capsule 100.
  • the below table shows the sealing strength of delivery walls having the same base structure and using different material for their connecting layers.
  • the base structure is the previously disclosed structure with filter layer 310, carrier layer 320, barrier layer 340 and the protective layer 350.
  • the sealing strength may be defined as the force necessary to detach /delaminate the delivery wall from the surface (rim portion of capsule body) it is attached to.
  • the sealing strength is given in Newton per 15 mm in relation to the bonding width. Table 1.
  • the sealing strength provided by a heat sealable coating is lower than the one obtained with the non-woven structures.
  • the sealing strength obtained with the heat sealable coating may in some cases not be high enough to withstand high extraction pressure of Nespresso® coffee machines or to withstand air freight conditions.
  • the sealing strength of the delivery wall on the rim portion 211 of the capsule body 200 is at least 6 N/15mm when measured according to ASTM F88/F88M-21 related to Standard Test Method for Seal Strength of Flexible Barrier Materials.
  • the delivery wall 300 comprises a connecting layer 330 made of a biodegradable/compostable non-woven material, preferably produced by a spun bond process which brings a high seal strength (higher 6N/15mm) when considering the prior art solutions. Due to the non-woven structure, the (high) thickness of the connecting layer 330 does not prevent the opening elements (pyramid plates) of the beverage extraction machine to pierce the delivery wall of the capsule and the coffee to flow through it.
  • the delivery wall 300 may comprise additional layers beside the filter layer 310, the carrier layer 320, the barrier layer 340, the protective layer 350 and the connection layer 330. These additional layers may be intercalated between different layers as needed and depending on their function.
  • a bonding layer 360 is interposed between the carrier layer 320 and the filter layer 310 to join them through adhesive bonding or heatsealing.
  • the carrier layer 320 and the filter layer 310 are at least partially joined to each other on opposite sides thereof, i.e. on their sides facing each other thanks to the bonding layer 360.
  • the bonding layer 360 may be made of one or more bonding layers and provides adhesive bonding between the carrier layer 320 and the filter layer 310 to ensure efficient adhesion of the two above-mentioned layers.
  • the bonding layer is also of a biodegradable and preferably compostable material, such as vegetable based starch or acrylic adhesive and participate to the biodegradable properties of the complete capsule.
  • Bonding strength of the bonding layer 360 may vary depending on the material of the filter layer 310 and carrier layer 320 but also depending on the material of the bonding layer 360.
  • the delivery wall 300 further comprises at least one adhesive layer 370 for adhesion of the connecting layer 330 to the protective layer 350.
  • the adhesive layer 370 in addition to providing the required adhesion between the connecting layer 330 and the protective layer 350 has also a protective effect (of the protective layer and barrier layer) during the lamination of the connecting layer 330 on the delivery wall structure.
  • the adhesive layer 370 may use material conventionally used bonding or sealing purpose. For example, commercially available sealing lacquer, adhesive polyester or polyurethane-based elastomer may be used.
  • the quantity of material used for the adhesive layer 370 is generally between 0.5 and 20 gsm to ensure efficient bond while keeping the opening properties of the delivery wall 300.
  • the non-woven structure of the connecting layer 330 is laminated onto the adhesive layer 370 which provides high bonding between the two layers but also protects the barrier layer 340 from moisture and thereby participate to maintaining the barrier performance of the barrier layer 340.
  • a delivery wall 300 according to the embodiment of Figure 1 or 2 having improved OTR performances with an OTR of less than 10 cc/m 2 /day, preferably less than 1 cc/m 2 /day, may be used in connection with the above-described capsule body 200 (of Figure 1 or 3) to provide a capsule 100 having improved shelf life and optimized extraction.
  • the filter layer 310 and carrier layer 320 are provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.
  • the carrier layer 320 faces the chamber 250.
  • the carrier layer 320 may be provided in the delivery wall closer to the chamber 250 than the filter layer 310. This is exemplarily illustrated in Figure 1 and in Figure 2.
  • each of the filter layer 310, the carrier layer 320 and the filter layer 340 may be made of a different biodegradable and preferably also compostable material.
  • the different materials of the three layers may distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation.
  • the elasticity of the filter layer 310 may be higher than the elasticity of the carrier layer 320, as, as typical for layered structures, layers being further away from the base layer undergo larger strain during bending compared to layers being closer thereto.
  • the delivery wall 300 may be provided opposite to the injection wall 220 with respect to the chamber 250.
  • the delivery wall 300 and the injection wall 220 may be provided with respect to each other such that in operation the injected fluid traverses the capsule 100 in the order of the injection wall 220, the chamber 250 (and, if available, the substance 500 contained therein), and the delivery wall 300.
  • the chamber 250 may be fully enclosed by the delivery wall 300 (on one end), the injection wall 220 (on an opposite end thereof) and the sidewall 210 (along/surrounding the sides between the two opposite ends).
  • the delivery wall 300 entirely extends over the opening 230 overlaps (with) the rim portion 211.
  • a further aspect of the present invention relates to a process for manufacturing the above-described capsule 100.
  • the capsule body 200 is formed from a biodegradable pulp material, such as cellulose pulp, bamboo pulp, bagasse pulp or wood pulp.
  • the injection wall 220 is formed (preferably along with the capsule body 200) such that at least a part of the chamber 250 for receiving the substance 500 for the preparation of the beverage is formed.
  • the delivery wall 300 is provided and attached to the capsule body 200, as above described e.g., by heat sealing. Therein, the delivery wall 300 is provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.
  • the capsule body 200 may be formed by wet pulp molding. Therein, a slurry of biodegradable pulp material, such as wood pulp, bagasse pulp, non-wood pulp, and/or cellulose based pulp in any form, may be pressed into a mold to form the capsule body 200. Thereafter, the so formed capsule body 200 is dried. At least a part of the inside surface (prior to filling) or at least a part of the outside surface of the capsule body 200 may be provided with the protective film 400, e.g., by thermoforming.
  • a slurry of biodegradable pulp material such as wood pulp, bagasse pulp, non-wood pulp, and/or cellulose based pulp in any form.
  • the so formed capsule body 200 is dried.
  • At least a part of the inside surface (prior to filling) or at least a part of the outside surface of the capsule body 200 may be provided with the protective film 400, e.g., by thermoforming.
  • the capsule body 200 may be formed by dry pulp molding. Therefore, a blank of preferably dried cellulose fibers may be provided, from which the capsule body 200 is formed with a tool preferably under the application of heat and/or water.
  • the protective film 400 may be applied as a liner on the inside of the capsule body 200 (for example by applying heat and/or a vacuum), which may extend on and cover the inwards facing surface of the sidewall 210 between both ends of the capsule body 200 and may extend and cover the rim portion 211 on its surface facing away from the chamber 250.
  • the injection wall 220 may be formed along with the capsule body 200, e.g., in the same step.
  • the injection wall 220 may be formed either by (wet/dry) pulp molding or by attachment, e.g., with a biodegradable adhesive, of a membrane or film as the injection wall 220 to the capsule body 200 after forming of the capsule body 200.
  • the injection wall 220 may be formed together with the capsule body 200 in the same process step while a second, separate process step may be needed for attaching the injection wall 220 with an adhesive.
  • the capsule body 200 may be filled with the substance 500 for the preparation of the beverage.
  • the delivery wall 300 may be provided and attached to the capsule body 200 thanks to the connecting layer 330 such that the carrier layer 320 may face (be directed towards) the chamber 250.
  • the protective film 400 may be added to a (circumferential) surface of the capsule 100, which is preferably made from a biodegradable and/or compostable material. At least a part of an inner facing or of an outer facing surface of the injection wall 220 (a surface which in addition may delimit the chamber 250) may be provided with the protective film 400.
  • the disclosed delivery wall 300 is hence composed of different layers of material each having specific properties and function and that are as a whole participating to the final properties of the delivery wall 300.
  • the delivery wall 300 may then comprise a layered structure or be proposed as laminated structure.
  • the general laminating manufacturing process is known in the prior art.
  • the specific arrangement of the one or more connecting layer 330 on the protective layer 350 or on the barrier layer 340 may be done using coating technology or printing technologies. If a coating is applied, the coating is, for example, water-based.
  • a further aspect of the invention relates to a system comprising the above-described capsule 100 and a beverage production machine and to the use of the above-described capsule 100 for preparing a beverage in a beverage production machine having a capsule holder.
  • the capsule 100 as described above may be provided and inserted in a brewing chamber of the beverage production machine.
  • the brewing chamber comprises a first part for hosting the capsule and a second part comprising a capsule holder having an opening structure.
  • the capsule 100 is placed in the beverage production machine such that the filter layer 310 is closer to (and eventually contacts) the opening structure (comprising opening elements in the form of a relief and recessed surface) of the capsule holder of the second part of brewing chamber of the machine than the carrier layer 320.
  • the brewing chamber is then closed.
  • the injection wall 220 of the capsule 100 may be perforated by an injection nozzle of the beverage production machine to inject a fluid in the chamber 250 to interact with the substance 500.
  • the fluid such as a liquid or a liq uid/gas mixture, may be injected into the chamber 250, thereby causing a pressure to build up in the capsule 100 and the delivery wall 300 is to thrust against opening elements, e.g. of the beverage production machine. At least part of the delivery wall 300 may be opened when the pressure of the injected fluid reaches a predetermined level in the chamber 250.
  • the carrier layer 320 may be perforated.
  • the delivery wall 300 may be provided such (e.g.
  • the carrier layer 320 may be perforated while the filter layer 310 is not per se perforated (as it has an open fiber structure).
  • the carrier layer 320 is perforated while the filter layer 310 remains integral.
  • the prepared beverage may be drained from the capsule 100, wherein the beverage may pass through openings in the carrier layer 320 and (cavities in the porous material of) the filter layer 310, wherein the carrier layer 320 may be closer to the chamber 250 than the filter layer 310 and the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.
  • the delivery wall 300 of the capsule in use in the closed brewing chamber is thus opened with reduced tearing by the relief and recessed surface of the opening structure, when compared with a capsule comprising an aluminium delivery wall.
  • the invention is also related to the use of a capsule and system as above described.
  • any reference signs placed between parentheses shall not be construed as limiting the claim.
  • the word 'comprising' does not exclude the presence of other elements or steps then those listed in a claim.
  • the terms "a” or "an,” as used herein, are defined as one or more than one.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Apparatus For Making Beverages (AREA)

Abstract

The invention relates to a capsule (100) for preparing a beverage in a beverage production machine, the capsule (100) comprising a capsule body (200) delimiting a chamber (250) for containing a beverage substance (500), an injection wall (220) closing the chamber at a first end and a delivery wall (300) closing the chamber (250) at a second end of the capsule body (200). The delivery wall (300) comprises in a layered manner a carrier layer (320) for carrying the subsequent layers, an optional filter layer (310) and a barrier layer (340) applied on the carrier layer (320), the barrier layer (310) providing a preferably bidirectional barrier against moisture and/or gas, the barrier layer (340), at least one protective layer (350) applied on the side of the barrier layer facing the chamber (250) for protecting the barrier layer at least against moisture, and a connecting layer (330), on the side of the delivery wall (300) facing the chamber (300) for connection of the delivery wall (300) to the rim portion (211). The connecting layer (330) is made of biodegradable material and comprise at least a non-woven aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co-adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof. The invention also relates to a system comprising the proposed capsule and to a use of the proposed capsule for preparing a beverage in a beverage production machine.

Description

COMPOSTABLE TOP LID STRUCTURE
FOR A BEVERAGE PREPARATION CAPSULE
Field of the Invention
The present invention relates to a capsule for preparing a beverage in a beverage production machine, to a system comprising the proposed capsule and to a use of the proposed capsule for preparing a beverage in a beverage production machine.
Background
Single-serve beverage capsules for beverage preparation machines are known in the art. These capsules are commonly used for on demand dispensing of beverages, like coffee, tea or hot chocolate, and enjoy popularity due to their fresh tasting, variability of flavors and the convenience of the beverage preparation.
Usually, the capsule containing a beverage component is inserted in a capsule holder of a beverage preparation machine, the capsule holder is closed, and the beverage preparation is started. Fluid, such as water or milk, is delivered to the capsule to interact with the beverage component contained inside the capsule to produce the desired beverage. When a sufficient amount of the fluid fills the capsule, the capsule opens under pressure of the fluid to release the prepared beverage. For example, opening of the capsule can be accomplished by pressing an extraction face of the capsule with a force effected by increasing pressure of the fluid inside the capsule against an opening structure provided in the capsule holder such that the extraction face is torn upon reaching a breaking stress thereof. The opening structure can be a number of relief and recessed elements, e.g., pyramid-like elements, onto which the extraction face extends and tears under the effect of the internal pressure of the fluid. Such pressure-controlled beverage preparation has the advantage that it can produce a beverage of high quality.
However, a high number of parameters and dynamic effects can influence the opening process of the capsule on the extraction face with the aforementioned opening structure and thus, repeatability and consistency in the opening process are difficult to achieve, which may have a negative impact on the result of the finished beverage. In particular, it has been found that the extraction face, generally in the form of a delivery wall, needs to show a certain amount of stiffness to ensure pressure built-up in the capsule while avoiding collapse thereof during the opening process. Conversely, the extraction face should be configured such that it can be torn by the opening structure in the opening process. Also, it is desirable that particles and fibers from the beverage component are retained inside the capsule to avoid not only contamination of the prepared beverage but also obstruction of openings in the capsule and/or the opening structure that are provided for dispensing the prepared beverage out of the beverage preparation machine.
In the prior art, these technical challenges are addressed, by forming the extraction face of a membrane made of aluminium with a very precisely controlled thickness, in particular, of about 30 to 40 micrometers. Aluminium offers a number of advantages, such as a high-pressure resistance, durability, flexibility, low weight, provision of long shelf-life and letting the taste of the prepared beverage unaltered. In addition to Aluminium capsules, some consumers are expecting capsules made of alternative material, and in particular capsules made of compostable material.
Therefore, recently various attempts were made to replace Aluminum material used in capsules with alternative materials. For example, bioplastics made from cornstarch or dried pulp made from sugarcane fiber were proposed to be used as capsule materials. However, a disadvantage of such materials is that they do not have the same material properties as presently used materials, like aluminium. For example, capsules made from alternative materials often have a limited shelf-life as they do not provide the same reliable oxygen and moisture barrier as aluminium.
In particular, the design of an extraction face with alternative materials appears to be challenging, as it is not possible to simply transfer the design principles and solutions applied for the former aluminium extraction face to these new materials. Approaches that, for example, simply replace the known aluminium formed extraction face with a paper-based material have proved unsuccessful, because the quality of the prepared beverages, reproducibility of flavors and beverage consistency were not comparable with the high standards set by the known aluminium-based extraction faces.
Additionally, even if some attempts in providing alternative compostable capsules are starting to be successful, the structure and the design of the capsule top lid membrane is still a challenge as the capsule membrane needs to fulfil multiple requirements. Indeed, the capsule top lid membrane should: be fully biodegradable and/or compostable, have optimum barrier properties for an improved shelf life of the capsule ingredient, be tight sealed to the capsule rim with a high seal strength, sustain air freight and not detach or delaminate from the capsule body especially in tropical conditions, have a structure and related materials allowing the capsule to be opened by the opening structure of the beverage preparation machine during the capsule opening process, sustain the pressure inside de beverage extraction machine and not burst nor delaminate during extraction, and provide optimized extraction.
Therefore, it is an object of the present invention to provide a capsule with a configuration and design that facilitates the use of compostable materials for the entire capsule while maintaining and/or exceeding the quality and continuity standards of the capsule itself and of the prepared beverage as set by a comparable aluminium capsule, especially with an improved top lid membrane as a delivery wall for the beverage to be delivered during extraction.
These and other objects, which become apparent upon reading the description, are solved by the subject-matter of the independent claims. The dependent claims refer to preferred embodiments of the invention.
Summary of the Invention
As used herein, the term "machine" or "device" may refer to an electrically operated device or machine that: can prepare, from a precursor material or ingredient, a beverage and/or foodstuff, or; can prepare, from a pre-precursor material, a precursor material that can be subsequently prepared into a beverage and/or foodstuff. The machine may implement said preparation by one or more of the following processes: dilution; heating; pressurization; cooling; mixing; whisking; dissolution; soaking; steeping; extraction; conditioning; infusion; grinding, and other like process. The machine may be dimensioned for use on a work top, e.g. it may be less than 70 cm in length, width and height. As used herein, the term "prepare" in respect of a beverage and/or foodstuff may refer to the preparation of at least part of the beverage and/or foodstuff (e.g. a beverage is prepared by said machine in its entirety or part prepared to which the end-user may manually add extra fluid prior to consumption, including milk and/or water). As a preference in the present invention, the beverage extraction device is a Nespresso Original Line extraction machine as described for example in one or more of EP0512468A1, EP0512470A1, EP1654966A1 or EP2142054A1.
The Nespresso® Original Line system when used with capsule made of aluminium, are disclosed along with their opening system, for example, in one or more of EP0512468A1, EP0512470A1, EP1646305A1 or EP1165398A1. In these references, constructional, manufacturing and/or (beverage) extraction details of such aluminium capsules and/or closing members are also disclosed.
In such system, the capsule is intended to be inserted into an extraction device, in which it can be pierced and injected with a fluid that passes through the bed of coffee contained in the capsule. The capsule is then opened against a supporting part of the device comprising raised elements (in the form of truncated pyramids) under the effect of the pressure of the fluid entering and rising in the capsule.
As used herein, the term "container" or "capsule" may refer to any configuration to contain the precursor material, e.g. as a single-serving, pre-portioned amount. The container may have a maximum capacity such that it can only contain a single serving of precursor material. The container may be single use, e.g. it is physically altered after a preparation process, which can include one or more of: perforation to supply fluid; for example a liquid like water, to the precursor material; perforation to supply the beverage/foodstuff from the container; opening by a user to extract the precursor material. The container may be configured for operation with a container processing unit of the machine, e.g. it may include a flange for alignment and directing the container through or arrangement on said unit. The container may include a rupturing portion, which is arranged to rupture when subject to a particular pressure to deliver the beverage/foodstuff. The container may have a membrane for closing the container. The container may have various forms, including one or more of: frustoconical; cylindrical; disk; hemispherical, and other like form. The container may be formed from various materials, such as metal or plastic or wood pulp based a combination thereof. As a preference in the present invention, the container is a compostable capsule, preferably made of cellulose and preferably made as a cellulose or wood pulp molded capsule. The material may be selected such that it is: food-safe; it can withstand the pressure and/or temperature of a preparation process. The container may be defined as a capsule, wherein a capsule may have an internal volume of 20 - 100 ml. The capsule includes a coffee capsule, e.g. a Nespresso® capsule (including a Classic/Original Line, Professional, or other capsule).
As used herein, the term "system" or "beverage or foodstuff preparation system" may refer to the combination of any two or more of: the beverage or foodstuff preparation machine; the container; the server system, and the peripheral device.
As used herein, the term "beverage" may refer to any substance capable of being processed to a potable substance, which may be chilled or hot. The beverage may be one or more of: a solid; a liquid; a gel; a paste. The beverage may include one or a combination of: tea; coffee; hot chocolate; milk; cordial; vitamin composition; herbal tea/infusion; infused/flavored water, and other substance. As used herein, the term "foodstuff" may refer to any substance capable of being processed to a nutriment for eating, which may be chilled or hot. The foodstuff may be one or more of: a solid; a liquid; a gel; a paste. The foodstuff may include yoghurt; mousse; parfait; soup; ice cream; sorbet; custard; smoothies; other substance. It will be appreciated that there is a degree of overlap between the definitions of a beverage and foodstuff, e.g. a beverage can also be a foodstuff and thus a machine that is said to prepare a beverage or foodstuff does not preclude the preparation of both. As a preference, the beverage is coffee including roast and ground coffee.
As used herein, the term "precursor material" or "ingredient" may refer to any material capable of being processed to form part or all of the beverage or foodstuff. The precursor material can be one or more of a: powder; crystalline; liquid; gel; solid, and other. Examples of a beverage forming precursor material include ground coffee; milk powder; tea leaves; coco powder; vitamin composition; herbs, e.g. for forming a herbal/infusion tea; a flavoring, and; other like material. Examples of a foodstuff forming precursor material include dried vegetables or stock as anhydrous soup powder; powdered milk; flour-based powders including custard; powdered yoghurt or ice-cream, and; other like material. A precursor material may also refer to any pre-precursor material capable of being processed to a precursor material as defined above, i.e. any precursor material that can subsequently be processed to a beverage and/or foodstuff. In an example, the pre-precursor material includes coffee beans which can be ground and/or heated (e.g. roasted) to the precursor material. As a preference, within the disclosed extraction process, the precursor material is roast and ground coffee.
As used herein, the term "fluid" (in respect of fluid supplied by a fluid conditioning system) may include one or more of a liquid, for example, water; milk; other. As used herein the term "wood pulp-based" may refer to the material or a portion of material forming the container which is one or more of: porous; fibrous; cellulosic; formed of cellulosic material; formed of natural cellulosic material; formed of reconstituted or regenerated cellulosic material; non-woven; is composed entirely of or is a composition of wood pulp, and is wet or dry formed. A thickness of the wood-based material may be 0.25 mm to 0.75 mm or about 0.5 mm. The wood-based material may be 200-400 gsm.
As used herein the term "non-woven" may refer to a fabric-like material which is not woven or knitted. A non-woven material may be made from bonded together fibers. As used herein the term "porous" may refer to material configured with interstices to transmit water (or other liquid) therethrough. As used herein the term "fibrous" may refer to material comprised of fibers, which may be present in one or more of the material constituents.
As used herein the term "cellulosic", "cellulose-based" or "cellulosic material" may refer to conventionally woody (from soft wood and/or hard wood species) and/or non- woody materials. These materials may be bleached and unbleached and may include a regenerated or reconstituted cellulose. Examples of softwood are Pine, Spruce, Redwood etc. Examples of hardwood are Maple, Oak, Ash, Eucalyptus, Maple, Birch, Walnut, Beech etc. Examples of non-woody origin cellulose-based material are rice, manila hemp, sisal, jute, bamboo, maize, sugar cane, sugar cane residues (bagasse), banana peels, coffee ground.
As used herein the term "natural cellulosic material" may refer to conventionally woody materials or non-woody materials, which are not regenerated. As used herein the term "reconstituted or regenerated cellulosic material" may refer natural cellulosic material subject to processing that comprises reconstitution or regeneration, examples include rayon and lyocell.
As used herein the term "wood pulp" may refer to a lignocellulosic fibrous material, which may be prepared by mechanical or chemical separation of cellulose fibers from one or more of wood, fiber crops, paper, or rags. As used herein the term "wet formed" may refer to a process of forming from an aqueous solution of fibers. The aqueous solution of fibers may be heated and pressed in a mold to set the material and remove water therefrom. As used herein the term "dry formed" may refer to a process of forming not using aqueous solution of fibers.
The capsule of the invention has the same design as a Nespresso® Original Line capsules and is fully made (capsule body and delivery wall) of compostable material, preferably of cellulose-based material, more preferably of pulp-molded cellulose-based material. The capsule is in the form of a frustoconical cup and has for example a diameter of 2 - 5 cm and an axial length of 2 - 4 cm.
In variant embodiments, which are not illustrated: the capsule may have other crosssection shapes, including square, other polygons, or elliptical; the flange or rim portion is alternatively connected to the upper surface of the closing member, e.g. by crimping; the sidewall is alternatively arranged, including with the reverse taper or is aligned to the depth direction, or is curved; the base is alternatively arranged, including with as flat or curved; the flange or rim portion is connected to the storage portion rather than being integrally formed; the closing member is arranged as a storage portion, e.g. it comprises a cavity, and; the flange portion is omitted, e.g. the closing member connects directly to the storage portion.
A first aspect of the invention relates to a capsule for preparing a beverage in a beverage production machine. In these respects, the invention provides a capsule according to Claim 1.
In more details, the capsule may be understood as a receptacle or container for containing a substance for preparing a beverage and preferably may form a case or container that surrounds the substance.
The capsule body is of a three-dimension shape. It delimits with its sidewall (at least part of), a chamber, which may be a compartment, a cavity or a hollow space in the capsule, for example. The chamber generally contains a beverage or foodstuff ingredient or substance for the preparation of the beverage. The capsule body also comprises a rim portion delimiting an opening in the sidewall. The capsule further comprises an injection wall closing the chamber at one end of the sidewall, and suitable for injecting a fluid in the chamber. Injection of the fluid may lead to an interaction of the fluid with the substance, which may include any kind of chemical and/or physical reaction between the substance and the fluid, such as wetting, infusion, extraction, dissolution, and/or any other kind of corresponding interaction to produce a beverage product. The capsule further comprises a delivery wall that is connected to the capsule body to close the chamber. For example, it may be conceivable that a space inside the capsule may be (completely) surrounded from all sides by the container body (sidewall), the injection wall and the delivery wall, preferably such that the chamber for receiving the substance is formed (and closed). Thereby, a capsule can be provided that can be filled with a substance for preparing a beverage and used with known capsule machines. The substance can be protected from degradation and outside influences, like oxidation or moisture, and flavors of the substance can be kept inside the capsule even when storing the same for extended periods.
The delivery wall of the invention is made of biodegradable materials and comprises in a layered manner and in this specific order (from the side facing away the capsule to the side facing the chamber of the capsule) a filter layer, a carrier layer, a barrier layer, a protective layer and a connecting layer for connection to the capsule body. Thus, the delivery wall may comprise different parts that are arranged in plies, slats, tiers or as strata. Thereby, it is possible to provide the delivery wall with an arbitrary number of layers that each can provide a desired functionality, such as, for example, a bonding layer for bonding one or more layers, and/or for purifying and/or sieving out certain particles or contents from the prepared beverage before the prepared beverage leaves the capsule (the chamber), such as with the filter layer. Therein, the delivery wall may have various (layer) configurations, forms and shapes.
The filter layer is provided for filtering out particles from the prepared beverage dispensed via the delivery wall. The filter layer is positioned in the delivery wall as facing away from the chamber. The filter layer is made of biodegradable and/or compostable material.
The carrier layer (also called retention layer) of the delivery wall is provided such that it may be opened upon pressure rinsing in the capsule and/or interaction with opening elements of a capsule holder (of a capsule chamber of the beverage production machine) under the effect of rising pressure of the fluid injected in the capsule, for example,) by relative movement between the respective elements. Therein, the opening elements may have various configurations, forms and shapes and may comprise a plurality of relief and recessed elements, e.g. pyramid-like elements. This design allows tailoring the design of the delivery wall to technical needs. As well, the carrier layer is made of biodegradable and/or compostable material.
As mentioned, each of the filter layer and the carrier layer is made of a biodegradable, preferably compostable material. This may lead to a more straightforward recovery of the organic material inside the capsule as well as of the capsule material itself.
The barrier layer is also made of biodegradable material. It provides a preferably bidirectional barrier against moisture and/or gas, the barrier layer is preferably made of a different material than the filter layer and/or the carrier layer; the barrier layer being applied on the surface of the carrier layer facing the chamber. In the proposed solution, the barrier properties are preferably against moisture and/or liquid and/or gaseous substance, preferably oxygen, entering and/or leaving the chamber.
It is proposed that the barrier layer is preferably made of a different material than the filter layer and/or the carrier layer as the expected physicochemical properties of the barrier layer are protection of the substance enclosed in chamber against moisture and/or oxygen and not any filtering or retention properties.
Preferably, each of the filter layer, the barrier layer and the carrier layer is made of a different biodegradable and preferably compostable material, wherein preferably the different materials distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation.
Therein, the expression "biodegradable material" may be understood as any material that can be broken down into environmentally innocuous products by (the action of) living things (such as microorganisms, e.g. bacteria, fungi or algae). This process could take place in an environment with the presence of oxygen (aerobic) and/or otherwise without presence of oxygen (anaerobic). This may be understood, for example, as meaning that composting can be carried out without reservation. In particular, at the end of a composting process there are no residues of the material, which may be problematic for the environment, or any non-biodegradable components.
Examples for biodegradable materials for the carrier layer or the filter layer may be different plant-based materials, such as wood, bamboo, bamboo fibres, cellulose, cellulose pulp, wood pulp, sugarcane pulp, paper and/or cardboard. In addition, bioplastic families such as biopolymers such as polyhydroxybutyrate (PHB) and co-polymers, polybutylene succinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A/PBSa), polylactide (PLA), polybutylene adipate terephthalate (PBAT), Cellulose Acetate, starch and/or compounds or combination of above mentioned materials are other examples.
International standards, e.g. EU 13432 or US ASTM D6400, specify technical requirements and procedures for determining compostability of a material. Biodegradation can be tested following standards such as ISO 14855, ISO 17556 or ISO 14851. For example, one of the tests requires that - in order to be considered as being "industrially compostable" - at least 90% of the material in question is biologically degraded under controlled conditions in 6 months. Similar tests exist also to enable home composting certification. According to the invention and as previously mentioned, the delivery wall further comprises at least one protective layer and a connecting layer.
The protective layer is applied on the side of the barrier layer facing the capsule's chamber for protecting the barrier layer at least against moisture.
The connecting layer is applied on the protective layer and forms the external layer of the delivery wall facing the chamber. It allows connection of the delivery wall to the rim portion of the capsule body.
Similarly, as the filter, the carrier and the barrier layers, the connecting layer is made of biodegradable material thereby participating in the biodegradability of the full structure.
Furthermore, the connecting layer comprises at least a non-woven aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co-adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof.
The proposed structure has the advantage of providing an increased amount of material for connection to the rim portion of the capsule body to improve the sealing of the delivery wall onto the capsule body while, thanks to the use of a non-woven material, managing the total thickness of the delivery wall to allow for its opening during extraction of the capsule in the beverage preparation machine.
The proposed materials for the connecting layer are not defined as having adhesive properties. However, they provide, upon (sealing) connection onto the rim portion of the capsule body, a high and efficient connection of the delivery wall on the capsule body.
As a proposed feature, the connecting layer has a grammage comprised between 30 and 180 g/m2, preferably between 35 and 120 g/m2.
The quantity of material of the proposed connecting layer is important when compared to the usual quantity of material used when the connection of the delivery wall and the capsule body is made using a heat-seal lacquer or a heat-sealable coating - generally between 10 and 20 g/m2 to provide sealing on the capsule and still allow for opening of the delivery membrane during extraction. The connecting layer of the delivery wall is sealed, preferably by heat-sealing or ultrasonic sealing, to the rim portion of the capsule body. The use of sealing technology combined with the higher quantity of material available for the sealing allows the seal strength between the delivery wall and the capsule body to be improved. With the proposed material for the connecting layer and sealing technology, the connection between these two elements resists to air freight and tropical conditions.
According to an additional feature, the capsule body and preferably the injection wall comprise a barrier layered and/or laminated, protective film extending onto the rim portion of the capsule body onto which the connecting layer of the delivery wall is sealed. The protective film may be in the form of a liner structure or in a form of a coating (applied in one or more layers). A protective film (also called liner) in the form of a multilayer biodegradable structure comprising polymers may be used. An example of which is disclosed in WO 2021/145764
The connecting layer and the protective film are then sealed together, and their respective material locally melted and mixed to provide high strength connection.
With the proposed material used for the connecting layer, the sealing strength of the delivery wall on the rim portion of the capsule body comprising the protective film, is at least 6 N/15 mm measured according to ASTM F88/F88M-21 related to Standard Test Method for Seal Strength of Flexible Barrier Materials.
The sealing strength between the delivery wall and the capsule body is improved over the compostable cellulose based capsule solutions using heat-seal lacquer for delivery wall/cup body connection, currently available on the market.
During connection of the delivery wall on the capsule body, the sealing of the connecting layer to the rim portion is limited to a peripheral portion of the connecting layer. Hence, once connected, two regions can be defined on the connecting layer: a first region at the periphery of the connecting layer and corresponding to the portion that is sealed to the protective film laminated or thermoformed on the capsule body having an improved connection with the capsule body, and a second region corresponding to the non-sealed portion of the connecting layer which thanks to the non-woven structure of the material, allows for opening of the delivery wall despite to thickness of the connecting layer. The proposed delivery wall structure integrating a non-woven connecting layer combines an improved sealing strength between the delivery wall and the capsule body with a higher thickness of the connecting layer while enabling optimized opening of the delivery wall despite the thickness of the connecting layer.
It is proposed that the connecting layer be obtained by spun bond, melt blown or stapple fibers process and applied on the delivery wall by lamination during the production process of the delivery wall. This allows for controlled production and precise application on the delivery wall.
Preferably, the connecting layer is obtained using a spun bond production process which allows to have a non-woven structure of controlled material density and thickness.
It is further proposed that the delivery wall further comprises at least one adhesive layer positioned between the protective layer and the connecting layer to ensure optimized bonding of the connecting layer onto the protective layer. As well, the adhesive layer helps protecting the barrier layer during lamination of the connecting layer on the delivery wall structure.
The adhesive layer is proposed to be biodegradable similarly as the other layers of the delivery wall. It may in particular comprise material such as a vegetable-based starch or acrylic adhesive polymers.
According to a further possible feature, the filter layer is made of a compostable and non-woven material, preferably cellulose fiber such as wood or non-wood fibers or sugarcane pulp.
Alternative material may be rayon fibers, aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co-adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof.
The filter layer has a grammage between 10 and 150 g/m2, preferably between 20 and 100 g/m2.
Having a filter layer with a grammage between 10 and 150 g/m2, preferably between 20 and 100 g/m2 allows ensuring efficient filtering of any particle of the substance enclosed in the capsule chamber, for example roast and ground coffee. Thereby, the characteristics of the filter layer can be set by defining its area density of material, i.e. as mass per unit of area. For example, the tensile strength of the filter layer can be improved by increasing the grammage of its material and/or by using a (non-woven) material comprising fibers of a defined length and/or with a defined fiber bonding. Moreover, the filtration capacity and/or the porosity of the filter layer can be modified, e.g. reduced to smaller particle diameters, by setting the filter layer's material characteristics accordingly. Thereby, it is possible to tailor the filter layer to the specific requirements of the beverage preparation.
According to an additional feature, the carrier layer is made of a material that is biodegradable and compostable and has a defined closed fiber structure with at least 50% of weight comprising paper, softwood, hard wood or non-woody material and combination thereof. In a preferred solution, the carrier layer is made of paper-based material.
When the carrier layer is cellulose based, it may have a grammage comprised between 20 and 150 g/m2, preferably between 30 and 100 g/m2.
As an alternative, the closed fiber structure corresponds to Polyhydroxy alkanoate (PHA), Polyhydroxy butyrate (PHB) and co-polymers, Polybutylene succinate (PBS/PBS-A), biopolyesters, Cellulose Acetate, starch, polyvinyl alcohol (PVOH), polymers or co-polymers where at least one of the monomer units is vinyl alcohol, compounds and/or laminates of the above-mentioned materials.
In accordance with the use of the capsule in a beverage preparation machine capable of feeding an amount of a fluid under pressure into the capsule, the carrier layer, preferably the material of the carrier layer, is configured such that it is resilient against a built-up pressure in the chamber between 1 and 20 bar, more preferred between 10 and 20 bar, most preferred between 12 and 18 bar.
According to the needs, the characteristics of the carrier layer can be adjusted. For example, the tensile strength of the carrier layer can be improved by increasing the grammage of its material.
In a preferred embodiment, the filter layer is provided opposite to the chamber with respect to the carrier layer. This particular order and orientation of the carrier layer and the filter layer with respect to the capsule body leads to a number of improvements. For example, it is observed that the pressure profile during the beverage preparation is more consistent and reproducible. Moreover, a better crema formation and extraction and a reduced concentration of particles and residues of the substance, e.g. roast and ground of coffee, is found with this configuration in the beverage.
Resulting from the above, the carrier layer may face the chamber or may be provided closer to the chamber than the filter layer. Therein, for example, the expression "facing" may be understood as being directed towards the respective reference object without necessarily having to be provided directly onto the respective reference object.
As mentioned, the delivery wall also comprises a barrier layer. The barrier layer provides a, preferably bidirectional, barrier against moisture and/or oxygen and is made of a biodegradable, preferably compostable, material, such as biopolymers, Polyglycolic acid (PGA), Polyvinyl alcohol (PVOH), Butanediol vinyl alcohol co-polymer (BVOH) or any vinyl alcohol co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above-mentioned materials.
Preferably, the barrier layer is made of a different material than the filter layer and/or the carrier layer. This allows benefiting from the different material properties of both the filter layer and the carrier layer.
The barrier layer is applied in one or more layers in a total quantity of 2 to 50 gsm (g/m2), preferably of 5 to 40 gsm (g/m2). The proposed total barrier layer quantity allows to have sufficient barrier material to provide a barrier effect.
As proposed, the barrier layer is applied on the surface of the carrier layer facing the chamber.
As an option and to improve the OTR performance of the delivery wall, the surface of the carrier layer on which the barrier layer is applied has preferably a surface roughness lower than 1,3 microns when measured according to ISO 3274. Oxygen transmission rate (OTR) is the measurement of the amount of oxygen gas that passes through a substance over a given period. It is mostly carried out on non-porous materials, where the mode of transport is diffusion. In the present case, it relates to the permeation of oxygen through a packaging material (delivery wall) to sensitive foods like coffee. OTR measurement methodology uses ASTM D3985/ISO 15105 with typical measured Test Area of 50cm2 with Analysis conditions: 23°C and 50% Relative Humidity. Surface roughness, often shortened to roughness, is a component of surface texture. It is quantified by the deviations in the direction of the normal vector of a real surface from its ideal form. Roughness measurement may use surface profile measurement using a profilometer. In the present case it is done using a contact or stylus profilometers (such as Smithers' portable Handysurf E-35B) which moves a loaded diamond probe across the surface and record the vertical movement of the stylus caused by the surface irregularities. Samples have been measured 15 times. Controlling the roughness of the carrier layer surface before applying the barrier layer ensures regular application of the barrier layer on a material surface having more closed pores thereby improving the barrier layer properties, especially in OTR performances.
Hence, with the proposed delivery wall structure comprising the filter layer, the carrier layer and the barrier layer made from the previously proposed material, the Oxygen Transmission Rate (OTR) of the delivery wall (300) is below 35 cc/m2/day, preferably below 10 cc/m2/day, most preferably below 1 cc/m2/day, measured according to ASTM D3985/ISO 15105 methodology.
The controlled surface roughness coupled to the total quantity of barrier material applied on the carrier layer allows for improved OTR performances of the delivery wall via a decrease in the OTR values. Hence a tighter capsule may be obtained.
According to a further feature the one or more protective layer is applied directly on the surface of the barrier layer facing the chamber of the capsule. As a proposal, the protective layer is applied in one or more protective layers in a total amount of 5 to 30 gsm (g/m2), preferably between 5 and 20 gsm (g/m2) and with a maximum total thickness of 20 microns.
With the proposed protective layer, the protection of the barrier layer is ensured, and it is thereby possible to guarantee that the barrier layer is fully protected during the lamination of the further layers on the delivery wall and from moisture (to which the barrier layer is generally sensitive).
The protective layer is made of a biodegradable and preferably compostable material, such as vegetable starch-based, protein-based, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof.
Furthermore, the protective layer is preferably non hydrosoluble to avoid its degradation by the moisture content of the substance enclosed in the chamber. The protective layer is also preferably made of a different material than the filter layer and/or the carrier layer to ensure proper separation of the physicochemical properties of the different layers. With this proposed improved structure of the delivery wall completed with a protective layer (applied in one or more layers), the OTR value of delivery wall of the delivery wall comprising the protective layer is less than 10 cc/m2/day and preferably less than 1 cc/m2/day.
The controlled surface roughness, the defined total quantity of barrier material applied on the carrier layer coupled with the application of a protective layer in one or more layers allows for further improved OTR performances of the delivery wall.
The proposed delivery wall with improved OTR performances and sealing strength properties participate in increasing the protection of the substance filled in the capsule chamber, generally roast and ground coffee, thereby increasing the shelf-life of the capsule itself for the benefit of the consumer.
As a proposed option, the delivery wall also comprises a bonding layer which allows to, at least partially, join the filter layer and the carrier layer to each other on opposite sides thereof, preferably through adhesive bonding or heat-sealing.
Specifically, the bonding layer is provided between the carrier layer and the filter layer to ensure efficient adhesion of the two above-mentioned layers.
The bonding layer is of a biodegradable and preferably compostable material, such as vegetable based starch or acrylic adhesive and participate to the biodegradable properties of the complete capsule.
Preferably, the different layers forming the delivery wall, namely, the filter layer, the bonding layer, the carrier layer, the barrier layer, the protective layer, the adhesive layer and the connecting layer, which can be each formed of one or more layers, are made of different biodegradable, preferably compostable, material.
In addition to the above, the delivery wall may comprise additional layers beside the filter layer, the carrier layer, and the adhesive layer. These additional layers may be intercalated between the filter layer, carrier and the adhesive layers as needed and depending on their function.
The different layers are preferably made of different materials that preferably distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation. By providing at least the aforementioned carrier layer, filter layer and barrier layer from different materials, it is possible to provide the delivery wall as a composite structure. However, it is also conceivable that the delivery wall may comprise multiple different layers, which preferably may be made from different materials. This may lead to the advantageous effect that the combination of the two or more constituent materials with different physical or chemical properties produce a structure with characteristics different from each of the individual components. Thereby, the interface of the capsule to the outside can be tailored to the technical needs of the application. For example, by providing each of the layers with a different tensile strength, the pressure built up inside the capsule can be controlled and defined as required. Thereby, for example, the capsule can be designed to produce a beverage according to the specifications of its recipe. Moreover, by providing the two layers from materials with a different fiber configuration it is possible to tailor material characteristics relevant for the interaction of the delivery wall with the prepared beverage to the individual application, such as defining the filtering capabilities of the delivery wall. Also, the difference of orientation of the individual layers of the delivery wall may lead to different stresses in the layers, which can be taken into consideration with the above configuration by selecting different materials. For example, the material of one of the layers may break at a lower pressure than the material of another layer but the structure may be kept together by the combined resistance of each material, which may support each other under the effect of pressure.
In particular, one or more of the different layers of the delivery wall, namely the filter layer, the bonding layer, the carrier layer, the barrier layer, the protective layer, the adhesive layer and the connecting layer, is laminated with the other layers of the delivery wall. Thanks to the lamination of one or more of the mentioned layers, it is possible to produce a blank foil that is cut or punched to form the delivery wall. Depending on the dimension of the blank, several delivery walls may be formed from the same blank.
As mentioned, the proposed capsule body and preferably the injection wall is preferably made of molded pulp fiber and comprises a layered and/or laminated, protective film.
In a proposed solution, the capsule body and the injection wall are made up of separate pieces or are integrally formed, e.g., as a one-piece. This opens different manufacturing options for the capsule body and/or injection wall. A further aspect of the present invention relates to a system for preparing a beverage comprising a capsule containing a beverage ingredient, preferably roast and ground coffee and as above described and a beverage production machine.
The proposed system makes use of a beverage production machine with a fluid dispensing device capable of feeding the capsule with an amount of a fluid, such as water, with a pressure between 2 bars and 20 bars at a first end of the capsule formed by the injection wall, and with a brewing chamber, comprising a first part for hosting the capsule and a second part for closing the brewing chamber. The second part of the brewing chamber comprises a capsule holder that comprises an opening structure (with opening elements) for engaging with the delivery wall of the capsule at the second end of the sidewall when the brewing chamber holding the capsule is closed. The opening structure comprises a relief and recessed surface facing, in use, the delivery wall, preferably the filter layer of the capsule.
According to the proposed embodiment, the delivery wall when in use in the closed brewing chamber, is opened with reduced tearing by the relief and recessed surface of the opening structure, when compared with a capsule comprising an aluminium delivery wall.
An additional aspect of the present invention relates to a use of a capsule as described above for preparing a beverage in a beverage production machine having a capsule holder. So, a beverage can be prepared in an advantageous and ecologically beneficial manner.
Brief description of the Drawings
The invention is further described with reference to the following examples. It will be appreciated that the invention as claimed is not intended to be limited in any way by these examples.
Embodiments of the present invention will now be described, by way of examples, with reference to the accompanying figures in which:
Figure 1 shows a schematic exploded view of a capsule according to an embodiment of the invention.
Figure 2 shows an enlarged schematic cross-section of a section of the delivery wall of the capsule of Figure 1 showing the different layers of the delivery wall. Figure 3 shows a detailed view of another embodiment of a capsule of the invention integrating the delivery wall of Figure 2.
Detailed description
As used in this specification, the words "comprises", "comprising", and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean including, but not limited to.
Any reference to prior art documents in this specification is not to be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.
The figures show different views, and aspects and features of a capsule 100 and related components of the present invention for preparing a beverage in a beverage production machine in accordance with the present invention. Figures 1 shows an exploded view of a schematic capsule according to an embodiment of the present invention whereas Figure 3 shows a detailed design of another embodiment of the capsule of the invention, and Figure 2 shows in schematic cross-section the detailed layer structure of the delivery wall of the capsule of the proposed invention.
The capsule 100 may have a composite structure and/or may be made from a composite material, which preferably may consist entirely of biodegradable and/or compostable materials.
The capsule 100 comprises a capsule body 200 with a three-dimensional shape with a sidewall 210. The capsule body 200 may have any shape or form, for example the capsule body may be in the form of a cup-shaped body. For example, the capsule body 200 may have a form that is suitable for the capsule 100 being inserted in a capsule holder of a (known) beverage production machine, for example a Nespresso® beverage production machine. The capsule body 200 may have a frustoconical, truncated-, cup- or bowl-shaped form. The capsule body 200 may have a circular cross-section. Thereby, for example, pressure related forces exerting on the capsule body 200 can be absorbed.
The capsule body 200 comprises a sidewall 210. The sidewall 210 delimits a chamber 250 inside the capsule 100. The sidewall 210 may be provided such that it encloses a continuous space inside the capsule body 100. This is shown exemplarily in Figure 1. The chamber 250 is arranged to receive and store a substance 500 for the preparation of the beverage. Therein, the substance 500 may be any type of (solid, liquid, at least partially soluble and/or percolate-able) matter of a particular or definite chemical constitution. Examples for substances 500 may be roasted ground coffee, instant coffee, tealeaves, syrup concentrate, fruit extract concentrate, a chocolate product, dehydrated edible substances, and/or combinations thereof depending on the extraction process taking place. Accordingly, examples for beverages that may be prepared may be coffee- or chocolate-based drinks, or other similar types of food. However, the above examples for the substance 500 and beverages are not to be seen as a complete enumeration. Instead, various other examples are conceivable.
The capsule body 200 may have an opening 230 to the chamber 250. The opening 230 may be on at least one of the capsule body's 200 opposite ends. For example, the substance 500 may be filled inside the capsule 100 through the opening 230. The substance 500 may fill the chamber 250 entirely. However, there may be a free space between the opening 230 and the filling level of the substance 500, which may be filled with an inert gas for keeping the substance 500 fresh. Preferably, a rim portion 211 of the sidewall 210 may delimit the opening 230. The rim portion 211 may have the form of a flange and extend from the sidewall 210, preferably away from the chamber 250. In operation, the capsule 100 may be placed on the rim portion 211 inside a capsule holder of a beverage production machine.
The sidewall 210 may be provided such that it forms a continuous mantle surface of the capsule body 200. For example, the sidewall 210 may have an inside surface facing the chamber 250 and an outside surface facing away from the chamber 250.
A protective film 400 for providing a preferably bidirectional barrier against moisture and/or oxygen for the substance 500 may be provided on the capsule body 200 and/or the sidewall 210. In Figure 1, the protective film 400 is exemplarily illustrated as being provided as a liner on the inside surface of the sidewall 210, which may extend up to and over the rim portion 211. The protective film 400 may be provided additionally or alternatively on the outside surface of the sidewall 210. Additionally, or alternatively, the protective film may be provided as a coating having similar barrier properties. Therein, the protective film 400 may be made of a biodegradable and preferably compostable material, such as biopolymers or bioplastic families such as PHA and co-polymers (including PHB), PBS, PBS-A, PLA, PBAT, Cellulose Acetate, starch, PGA, PVOH, and it may include any polymers or co-polymers where at least one of the monomer units is vinyl alcohol (for example BVOH, Butenediol vinyl alcohol), as well as compounds or laminates of any of the above-mentioned materials. Preferably, the protective film 400 may be made of a food safe material (FCS, FCMs).
For example, the capsule body 200 may be made of (wet/dry) molded pulp fiber. Preferably, the capsule body 200 may be made of a biodegradable and/or compostable material. The capsule body 200 may be made of a food safe material (FCS, FCMs). The capsule body 200 may comprise a layered and/or laminated structure. For example, the capsule body 200 may be relatively stiff or rigid so not to collapse during operation in a beverage production machine or during storage. The layered and/or laminated design may provide the capsule body 200 with additional rigidity and/or stiffness in comparison to other designs. Therein, the molded pulp fiber may be a composite having an additional substrate, such as biodegradable resin, laminated on the capsule body 200. For example, a laminated structure of the capsule body 200 may be created by providing the protective film 400 thereon. However, it is also conceivable that the capsule body 200 may comprise, for example, in addition to the protective film 400 a further laminate film or layer.
Alternatively, the capsule body 200 may be made of paper-based material or of a paper-based material with a laminate, specifically shaped to delimit a chamber 250.
In the present case, the capsule body 200 is made of cellulose base pulp molded material, preferably woold pulp material using a wet pulp molding process.
The capsule 100 comprises an injection wall 220 for injecting a fluid in the chamber 250 for preparing the beverage upon interaction of the fluid with the substance 500. This is exemplarily illustrated in Figure 1.
The injection wall 220 may be provided on an opposite end of the capsule body 200 to the opening 230. The injection wall 220 may be provided integrally or separately with the capsule body 200. Hence, the capsule body 200 and the injection wall 220 may be made up of separate pieces or may be integrally formed as a one-piece. The injection wall 220 may form a tapered end portion of the capsule body 200. The injection wall 220 may be configured to be perforated by blades of the coffee production machine such that the blades provide openings for the fluid injection. Preferably, the fluid may be a liquid or a liq uid/gas mixture, such as water or milk. As the capsule body 200, the injection wall 220 may comprise also the above-described protective film 400. It is also conceivable, that the injection wall 220 may comprise (small) openings through which blades of the coffee production machine can enter and pierce the protective film 400. Like the capsule body 200, the injection wall 220 may comprise a layered and/or laminated structure and may be made of (laminated) molded pulp fiber and/or a food safe material (FCS, FCMs).
The capsule body 200 and the injection wall 220 may be provided such that the chamber 250 is closed (sealed) preferably from at least three sides as shown in Figure 1. The capsule body 200 and the injection wall 220 may be provided such that the injected fluid is dispersed evenly in the chamber 250 along the sidewall 210.
An alternative and detailed capsule body 200 is proposed in Figure 3 in which, in addition to the integral injection wall 220 and rim portion 211, the capsule comprises a tapered sidewall 210, a stacking rim 280 and a base portion 260 comprising stiffening ribs 270 and the injection wall 220. The capsule body 200 is disclosed in detail, for example, in WO2023/051967 Al and WO2023/052352 Al, the content of which is incorporated by reference. The capsule body 200 of Figure 3 is closed by a delivery wall (not presented in the figure) similar to the one disclosed in connection with Figure 1 and Figure 2.
The capsule 100 comprises a delivery wall 300, which is connected to the capsule body 200 to close the chamber 250. This is exemplarily indicated in Figure 1 and in Figure 2.
The delivery wall 300 is provided in a layered manner as exemplarily shown in Figure 1. There is no limitation on the number of (different) layers the delivery wall 300 may have. In Figure 1, only the main layers of the delivery wall are presented while in Figure 2 additional layers are added for connecting purpose between the main layers.
The delivery wall 300 is flat. The word "flat" shall mean that the delivery wall 300 extends substantially in one plane. In other words, the delivery wall 300 extends in one plane, but it can be deformed in a convex or concave plane, depending on the relative pressure between the inside and the outside of the capsule. In particular, it can happen that the ingredient contained therein (e.g., roast and ground coffee) will produce gases such as carbon dioxide over the storage period of the pod. In this case, an overpressure can be created within the capsule, which forces the - initially flat - delivery wall to bulge outside. It can also happen that the atmospheric pressure varies around the capsule, for instance if the capsule is formed, filled and sealed at a factory which is near sea level, and then said capsule is transported at a higher altitude, where the atmospheric pressure is lower. In such case, the - initially flat - delivery will deflect inwardly in a concave shape. As presented in Figure 1, the delivery wall comprises: o a filter layer 310 for filtering out particles from the prepared beverage dispensed via the delivery wall, o a carrier layer 320 being adapted to be opened under the effect of rising pressure of the fluid being injected into the capsule, o a barrier layer 340 for providing a preferably bidirectional barrier against moisture and/or gas and applied on the surface of the carrier layer 320 facing the chamber 250 of the capsule body 200, o a protective layer 350 applied on the side of the barrier layer facing the chamber 250 for protecting the barrier layer 340 at least against moisture, and o a connecting layer 330 applied as an external layer on the side of the delivery wall 300 facing the chamber 250 for connection of the delivery wall 300 to the rim portion 211 of the capsule body 200.
The delivery wall 300 is intended to be connected to the protective film 400 applied (by lamination / thermoforming) on the inner walls of the chamber 250 and on the rim portion 211 of the capsule body. Preferably, the delivery wall 300 is sealed to the protective film 400 at the location of the rim portion 211.
The filter layer 310, the carrier layer 320 the barrier layer 340, the protective layer 350 and the connecting layer 330 are all made of biodegradable, preferably compostable, material and are presently made of different material.
The filter layer 310 may be configured to filter out particles from the prepared beverage before dispensing the same via (from) the delivery wall 300. The filter layer 310 may be a film, membrane or ply of a defined thickness (and/or with a (largely) planar surface).
As proposed, the filter layer 310 is made of biodegradable material. Preferably, the filter layer 310 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also.
In the proposed embodiment, the filter layer 310 is made of a non-woven material, such as cellulose fibers from wood pulp (soft or hard wood material), or from non-woody material like sugarcane, bamboo, or hemp. Alternative material like PLA, rayon fibers, PBS, PBS-A, PHB, PBAT, PBSeT, their respective copolymers and combination thereof may also be selected.
The mechanical and filtering properties of the filter layer 310 may be influenced by the thickness of the material, its density as well as its permeability for particles. The filter layer 310 may have a thickness of material of 10 to 300 micrometers, preferably 20 to 250 micrometers. Additionally, or alternatively, the filter layer 310 may have a grammage between 10 and 150 gm (g/m2), preferably between 20 and 100 gsm (g/m2).
The carrier layer 320 is adapted to be opened under the effect of rising pressure of the fluid being injected in the capsule 100 during extraction in the beverage preparation machine. The carrier layer 320 may be a film, membrane or ply with a defined thickness and preferably with a substantially planar surface.
The carrier layer 320 is also made of biodegradable material. Preferably, the carrier layer 320 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also.
In the proposed solution, the (material of the) carrier layer 320 has a defined fiber structure, such as a closed fiber structure. For example, the carrier layer 320 material may be a fiber structure with at least 50% of weight corresponding to cellulose fibers, comprising paper, softwood, hardwood, or non-woody material.
The carrier layer 320 may be provided such that it is resilient against a built-up pressure in the chamber 250, preferably between 1 and 20 bar, more preferred between 10 and 20 bar, most preferred between 12 and 18 bar. In particular, the material of the carrier layer 320 may be configured such that it is resilient against a built-up pressure in the chamber 250 within such pressure ranges. Therein, the thickness and density of the material may influence the stiffness, i.e., the resistance to a bend, of the carrier layer 320. The carrier layer 320 may have a thickness of material of 0 to 150 micrometers, preferably 30 to 70 micrometers. Alternatively, or additionally, the carrier layer 320 may have a grammage between 20 and 150 g/m2, preferably between 40 and 100 g/m2.
As presented in Figure 1 and 2, the delivery wall 300 also comprises a barrier layer 340 which provides a barrier against moisture and/or oxygen. The barrier is chosen to be a bidirectional barrier against moisture and oxygen to preserve the substance 500, preferably roast and ground coffee, from the moisture and oxygen present outside the capsule. The bidirectional barrier layer 340 acts against liquid and/or gaseous substances/contents entering or leaving the chamber 250. With such an arrangement, the substance 500 keeps its initial quality and does not alter over time.
The barrier layer 340 is positioned on the side of the carrier layer 320 facing the capsule opening 230. It is indeed positioned closest to the opening 230 of the capsule so as to allow keeping all the nutritional properties and aromas of the substance 500.
The barrier layer 340 may be provided in the form of a single layer or in the form of multiple layers and its total thickness may vary between 1 micrometer and 10 micrometers. The amount of barrier material in one barrier layer 340 may be comprised between 0,1 to 10 gsm (g/m2) for a total quantity in the total number of barrier layers 340 of 2 to 50 gsm, preferably of 5 to 40 gsm.
It is made of a biodegradable, preferably compostable material comprising Polyglycolic acid (PGA), polyvinyl alcohol (PVOH) or copolymers, or butanediol vinyl alcohol co-polymer (BVOH) or any polymers or co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above-mentioned materials.
In the present case, the barrier layer 340 is made of BVOH (Butanediol vinyl alcohol co-polymer) or co-polymer. The barrier layer is applied in several layers and has a total thickness between 3 and 4 micrometers. The total thickness of the barrier layer should not exceed 10 micrometers and 50 gsm as it would bring the risk of non-piercing or bad-piercing of the delivery wall during extraction of the capsule.
In the delivery wall 300 of Figures 1 and 2; the barrier layer 340 is directly applied on the surface of the carrier layer 320 that is facing the capsule chamber 250 when the delivery wall 300 is sealed onto the capsule body 200.
The associated Oxygen Transmission Rate (OTR) (measured in cc/m2/day) of the delivery wall 300 presented in Figure 1 and 2 is measured as being below 10 cc/m2/day and in some cases depending on the material selection for the different layers, below 1 cc/m2/day.
The surface of the carrier layer 320 onto which the barrier layer 340 is applied may be controlled / treated to have a reduced surface roughness with the aim of further improving the OTR.
As presented in Figure 1, the delivery wall 300 also comprises at least one protective layer 350 applied on the side of the barrier layer 340 facing towards the chamber 250. The protective layer 350 is applied directly on the barrier layer 340 and aims at protecting the barrier layer 340 against moisture and/or oxygen to ensure optimized oxygen barrier performance of the barrier layer. The protective layer 350 also protects the barrier layer 340 during the lamination of the subsequent layers (connecting layer for example) during the production of the delivery wall 300.
The protective layer 350 is preferably applied in several layers so as to enhance the protecting effect of the protective layer for the barrier layer 340.
The protective layer 350 is made of a biodegradable and preferably compostable material and participate to the full biodegradability of the delivery wall 300.
To efficiently protect the barrier layer 340, the protective layer 350 may be made from a material that is preferably non-hydrosoluble, such as vegetable starch-based, proteinbased, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof. Commercially availableproducts from different companies like BASF, Henkel or Sun Chemicals may be used.
The total amount of material for protective layer, preferably applied in several layers, is comprised between 5 and 30 gsm (g/m2), preferably between 5 and 20 gsm (g/m2). The selected material and amount of material allows limiting the thickness of the protective layer 350 to a maximum total thickness of 20 microns. indeed, the quantity of material thickness of the protective layer (applied in one or more layers) should not respectively exceed 40 to 50 gsm and 30 microns the due to possible issue on piercing of the delivery wall during extraction.
In addition to the previously discussed layers and as presented in the figures, the delivery wall 300 comprises a connecting layer 330 to connect the delivery wall 300 to the rim portion 211 of the capsule body 200 to close the chamber 250, thereby forming a closed capsule 100.
The connecting layer 330 is hence applied as the external layer on the side of the delivery wall 300 facing the chamber 250 for connection of the delivery wall 300 to the rim portion 211.
As understood and as can be seen in Figure 1, the connecting layer 330 is connected to the rim portion 211 of the capsule body comprising the protective film 400. The protective film 400 and the connecting layer 330 are then bonded together to ensure tight closure of the capsule 100.
The material of the connecting layer 330 is selected to be biodegradable and preferably compostable and is selected material to be non-hydrosoluble to avoid any interaction with / degradation by the moisture content of the beverage substance 500 which may be, for example, roast and ground coffee, contained in the chamber 250.
It is proposed that the material of the connecting layer 330 be selected to comprise a non-woven aliphatic or aliphatic aromatic polyester or a combination thereof.
The non-woven material may be selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co- adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co- terephthalate (PBSeT), and their respective copolymers, and combination thereof.
Thanks to non-woven structure of the connecting layer 300, it is possible to have a grammage of the material of the connecting layer comprises between 25 and 150 g/m2, preferably between 35 and 100 g/m2 with limited impact on the delivery wall opening and on the extraction during the extraction of the capsule.
The connecting layer 330 may be obtained by spun bond, melt blown or stapple fibers process. However, additional production process leading to non-woven structure may be considered.
The connecting layer is applied on the delivery wall 300 by lamination during the production of the delivery wall 300.
The connecting layer 330 is sealed, preferably by heat-sealing or ultrasonic sealing, or connected by adhesive connection, to protective film 400 at the location of the rim portion 211 of the capsule body 200 to form the final capsule 100.
The below table shows the sealing strength of delivery walls having the same base structure and using different material for their connecting layers. The base structure is the previously disclosed structure with filter layer 310, carrier layer 320, barrier layer 340 and the protective layer 350. The sealing strength may be defined as the force necessary to detach /delaminate the delivery wall from the surface (rim portion of capsule body) it is attached to. The sealing strength is given in Newton per 15 mm in relation to the bonding width. Table 1.
As visible from table 1, the sealing strength provided by a heat sealable coating is lower than the one obtained with the non-woven structures.
From the tests done, the sealing strength obtained with the heat sealable coating may in some cases not be high enough to withstand high extraction pressure of Nespresso® coffee machines or to withstand air freight conditions.
Additional grammage for the heat sealable coating connecting member could not be tested as higher grammage, even if providing higher sealing strengths, are not offering efficient piercing or are resulting in no piercing of the delivery wall at all.
Resulting from the above presented test results, with the proposed structure and material for the connecting layer 330, the sealing strength of the delivery wall on the rim portion 211 of the capsule body 200 (comprising the protective film 400) is at least 6 N/15mm when measured according to ASTM F88/F88M-21 related to Standard Test Method for Seal Strength of Flexible Barrier Materials. As proposed, the delivery wall 300 comprises a connecting layer 330 made of a biodegradable/compostable non-woven material, preferably produced by a spun bond process which brings a high seal strength (higher 6N/15mm) when considering the prior art solutions. Due to the non-woven structure, the (high) thickness of the connecting layer 330 does not prevent the opening elements (pyramid plates) of the beverage extraction machine to pierce the delivery wall of the capsule and the coffee to flow through it.
Thanks to the proposed non-woven structure and high grammage of material of the connecting layer 330, it is possible to provide a high seal strength (heat) sealable delivery wall while still allowing optimized piercing of the delivery wall and coffee extraction.
The delivery wall 300 may comprise additional layers beside the filter layer 310, the carrier layer 320, the barrier layer 340, the protective layer 350 and the connection layer 330. These additional layers may be intercalated between different layers as needed and depending on their function.
For example, as proposed in Figure 2, a bonding layer 360 is interposed between the carrier layer 320 and the filter layer 310 to join them through adhesive bonding or heatsealing.
Hence, the carrier layer 320 and the filter layer 310 are at least partially joined to each other on opposite sides thereof, i.e. on their sides facing each other thanks to the bonding layer 360. The bonding layer 360 may be made of one or more bonding layers and provides adhesive bonding between the carrier layer 320 and the filter layer 310 to ensure efficient adhesion of the two above-mentioned layers.
The bonding layer is also of a biodegradable and preferably compostable material, such as vegetable based starch or acrylic adhesive and participate to the biodegradable properties of the complete capsule.
Bonding strength of the bonding layer 360 may vary depending on the material of the filter layer 310 and carrier layer 320 but also depending on the material of the bonding layer 360.
As also visible in Figure 2, the delivery wall 300 further comprises at least one adhesive layer 370 for adhesion of the connecting layer 330 to the protective layer 350. The adhesive layer 370, in addition to providing the required adhesion between the connecting layer 330 and the protective layer 350 has also a protective effect (of the protective layer and barrier layer) during the lamination of the connecting layer 330 on the delivery wall structure.
The adhesive layer 370 may use material conventionally used bonding or sealing purpose. For example, commercially available sealing lacquer, adhesive polyester or polyurethane-based elastomer may be used. The quantity of material used for the adhesive layer 370 is generally between 0.5 and 20 gsm to ensure efficient bond while keeping the opening properties of the delivery wall 300.
In the present case, the non-woven structure of the connecting layer 330 is laminated onto the adhesive layer 370 which provides high bonding between the two layers but also protects the barrier layer 340 from moisture and thereby participate to maintaining the barrier performance of the barrier layer 340.
The above presented additional layers are not impacting neither reducing the previously presented results concerning the OTR performances of the delivery wall 300.
Hence a delivery wall 300 according to the embodiment of Figure 1 or 2 having improved OTR performances with an OTR of less than 10 cc/m2/day, preferably less than 1 cc/m2/day, may be used in connection with the above-described capsule body 200 (of Figure 1 or 3) to provide a capsule 100 having improved shelf life and optimized extraction.
With the proposed delivery wall embodiment presented in Figure 1 and 2, the filter layer 310 and carrier layer 320 are provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.
In the examples, the carrier layer 320 faces the chamber 250. Alternatively, or additionally, the carrier layer 320 may be provided in the delivery wall closer to the chamber 250 than the filter layer 310. This is exemplarily illustrated in Figure 1 and in Figure 2.
Preferably, each of the filter layer 310, the carrier layer 320 and the filter layer 340 may be made of a different biodegradable and preferably also compostable material. The different materials of the three layers may distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation. For example, it may be preferred that the elasticity of the filter layer 310 may be higher than the elasticity of the carrier layer 320, as, as typical for layered structures, layers being further away from the base layer undergo larger strain during bending compared to layers being closer thereto. As shown in the Figures, the delivery wall 300 may be provided opposite to the injection wall 220 with respect to the chamber 250. The delivery wall 300 and the injection wall 220 may be provided with respect to each other such that in operation the injected fluid traverses the capsule 100 in the order of the injection wall 220, the chamber 250 (and, if available, the substance 500 contained therein), and the delivery wall 300. The chamber 250 may be fully enclosed by the delivery wall 300 (on one end), the injection wall 220 (on an opposite end thereof) and the sidewall 210 (along/surrounding the sides between the two opposite ends). The delivery wall 300 entirely extends over the opening 230 overlaps (with) the rim portion 211.
A further aspect of the present invention relates to a process for manufacturing the above-described capsule 100.
Therein, the capsule body 200 is formed from a biodegradable pulp material, such as cellulose pulp, bamboo pulp, bagasse pulp or wood pulp. The injection wall 220 is formed (preferably along with the capsule body 200) such that at least a part of the chamber 250 for receiving the substance 500 for the preparation of the beverage is formed. The delivery wall 300 is provided and attached to the capsule body 200, as above described e.g., by heat sealing. Therein, the delivery wall 300 is provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.
Preferably, the capsule body 200 may be formed by wet pulp molding. Therein, a slurry of biodegradable pulp material, such as wood pulp, bagasse pulp, non-wood pulp, and/or cellulose based pulp in any form, may be pressed into a mold to form the capsule body 200. Thereafter, the so formed capsule body 200 is dried. At least a part of the inside surface (prior to filling) or at least a part of the outside surface of the capsule body 200 may be provided with the protective film 400, e.g., by thermoforming.
Alternatively, the capsule body 200 may be formed by dry pulp molding. Therefore, a blank of preferably dried cellulose fibers may be provided, from which the capsule body 200 is formed with a tool preferably under the application of heat and/or water. The protective film 400 may be applied as a liner on the inside of the capsule body 200 (for example by applying heat and/or a vacuum), which may extend on and cover the inwards facing surface of the sidewall 210 between both ends of the capsule body 200 and may extend and cover the rim portion 211 on its surface facing away from the chamber 250. In both of the two aforementioned processes, the injection wall 220 may be formed along with the capsule body 200, e.g., in the same step. Preferably, the injection wall 220 may be formed either by (wet/dry) pulp molding or by attachment, e.g., with a biodegradable adhesive, of a membrane or film as the injection wall 220 to the capsule body 200 after forming of the capsule body 200. For example, by (wet/dry) pulp molding the injection wall 220 may be formed together with the capsule body 200 in the same process step while a second, separate process step may be needed for attaching the injection wall 220 with an adhesive. The capsule body 200 may be filled with the substance 500 for the preparation of the beverage. The delivery wall 300 may be provided and attached to the capsule body 200 thanks to the connecting layer 330 such that the carrier layer 320 may face (be directed towards) the chamber 250. The protective film 400 may be added to a (circumferential) surface of the capsule 100, which is preferably made from a biodegradable and/or compostable material. At least a part of an inner facing or of an outer facing surface of the injection wall 220 (a surface which in addition may delimit the chamber 250) may be provided with the protective film 400.
As disclosed, the disclosed delivery wall 300 is hence composed of different layers of material each having specific properties and function and that are as a whole participating to the final properties of the delivery wall 300.
The delivery wall 300 may then comprise a layered structure or be proposed as laminated structure. The general laminating manufacturing process is known in the prior art.
The specific arrangement of the one or more connecting layer 330 on the protective layer 350 or on the barrier layer 340 may be done using coating technology or printing technologies. If a coating is applied, the coating is, for example, water-based.
A further aspect of the invention relates to a system comprising the above-described capsule 100 and a beverage production machine and to the use of the above-described capsule 100 for preparing a beverage in a beverage production machine having a capsule holder.
For example, the capsule 100 as described above may be provided and inserted in a brewing chamber of the beverage production machine. The brewing chamber comprises a first part for hosting the capsule and a second part comprising a capsule holder having an opening structure. During the extraction process, the capsule 100 is placed in the beverage production machine such that the filter layer 310 is closer to (and eventually contacts) the opening structure (comprising opening elements in the form of a relief and recessed surface) of the capsule holder of the second part of brewing chamber of the machine than the carrier layer 320. The brewing chamber is then closed.
The injection wall 220 of the capsule 100 may be perforated by an injection nozzle of the beverage production machine to inject a fluid in the chamber 250 to interact with the substance 500. The fluid, such as a liquid or a liq uid/gas mixture, may be injected into the chamber 250, thereby causing a pressure to build up in the capsule 100 and the delivery wall 300 is to thrust against opening elements, e.g. of the beverage production machine. At least part of the delivery wall 300 may be opened when the pressure of the injected fluid reaches a predetermined level in the chamber 250. Preferably, the carrier layer 320 may be perforated. Alternatively, or additionally, the delivery wall 300 may be provided such (e.g. with regards to its material configuration/selection) that the carrier layer 320 may be perforated while the filter layer 310 is not per se perforated (as it has an open fiber structure). In this preferred embodiment, the carrier layer 320 is perforated while the filter layer 310 remains integral. The prepared beverage may be drained from the capsule 100, wherein the beverage may pass through openings in the carrier layer 320 and (cavities in the porous material of) the filter layer 310, wherein the carrier layer 320 may be closer to the chamber 250 than the filter layer 310 and the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.
The delivery wall 300 of the capsule in use in the closed brewing chamber is thus opened with reduced tearing by the relief and recessed surface of the opening structure, when compared with a capsule comprising an aluminium delivery wall.
As previously mentioned, the invention is also related to the use of a capsule and system as above described.
It should be understood that various changes and modifications to the presently preferred embodiments of the capsules described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the scope of the present invention covered by the appended claims.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word 'comprising' does not exclude the presence of other elements or steps then those listed in a claim. Furthermore, the terms "a" or "an," as used herein, are defined as one or more than one. Also, the use of introductory phrases such as "at least one" and "one or more" in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an." The same holds true for the use of definite articles. Unless stated otherwise, terms such as "first" and "second" are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.
Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, example or claims prevent such a combination, the features of the foregoing embodiments and examples, and of the following claims may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of the example(s), embodiment(s), or dependency of the claim(s). Moreover, this also applies to the phrase "in one embodiment", "according to an embodiment" and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an', 'one' or 'some' embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment.
The foregoing description of one or more implementations provides illustration and description but is not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of various implementations of the present disclosure.

Claims

Claims
1. A capsule (100) for preparing a beverage in a beverage production machine, wherein the capsule (100) comprises:
- a capsule body (200) comprising a sidewall (210) delimiting a chamber (250) for containing a substance (500) forthe preparation of the beverage, and a rim portion (211) delimiting an opening (230) in the sidewall (210);
- an injection wall (220), closing the chamber at a first end, for injecting a fluid in the chamber (250) for preparing the beverage upon interaction of the fluid with the substance (500); and
- a delivery wall (300) being connected to the capsule body (200), preferably to the rim portion (211), to close the chamber (250) at a second end of the capsule body (200), the delivery wall (300) comprising in a layered manner and in this order: o a filter layer (310), facing away from the chamber (250) made of biodegradable material for filtering out particles from the prepared beverage dispensed via the delivery wall (300), o a carrier layer (320) made of biodegradable material, the carrier layer (320) being adapted to be opened under the effect of rising pressure of the fluid being injected into the capsule (100), and o a barrier layer (340) made of biodegradable material for providing a preferably bidirectional barrier against moisture and/or gas, the barrier layer (340) being preferably made of a different material than the filter layer (310) and/or the carrier layer (320); the barrier layer (340) being applied on the surface of the carrier layer (320) facing the chamber (250). wherein the delivery wall (300) further comprises: o at least one protective layer (350) applied on the side of the barrier layer facing the chamber (250) for protecting the barrier layer at least against moisture, and o a connecting layer (330) applied as an external layer on the side of the delivery wall (300) facing the chamber (250) for connection of the delivery wall (300) to the rim portion (211), made of biodegradable material and comprising at least a non-woven aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate-co-adipate (PBSA), Polybutylene adipate-co- terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof.
2. The capsule (100) according to claim 1, wherein the connecting layer (330) has a grammage between 25 and 180 g/m2, preferably between 35 and 120 g/m2.
3. The capsule (100) according to claim 1 or 2, wherein the connecting layer (330) is sealed, preferably by heat-sealing or ultrasonic sealing, to the rim portion (211) of the capsule body (200).
4. The capsule (100) according to any one of the preceding claims, wherein the capsule body (200) and preferably the injection wall (220) further comprises a barrier, layered and/or laminated, protective film (400) extending onto the rim portion (211) of the capsule body (200) onto which the connecting layer (330) of the delivery wall (300) is sealed.
5. The capsule (100) according to any one of the preceding claims, wherein the sealing strength of the delivery wall on the rim portion (211) of the capsule body (200) comprising the protective film (400) is at least 6 N/15 mm measured according to ASTM F88/F88M-21 related to Standard Test Method for Seal Strength of Flexible Barrier Materials.
6. The capsule (100) according to any one of claims 3 to 5, wherein the sealing of the connecting layer (330) to the rim portion (211) is limited to the periphery of the connecting layer (330) thereby defining, in the connecting layer (330), two regions having different technical properties.
7. The capsule (100) according to any one of the preceding claims, wherein the connecting layer (330) is obtained by spun bond, melt blown or stapple fibers process and applied on the delivery wall by lamination during production of the delivery wall (300).
8. The capsule (100) according to any one of the preceding claims, wherein the filter layer (310) is made of a compostable and non-woven material, preferably cellulose fiber such as wood or non-wood fibers or sugarcane pulp, or rayon fibers, or an aliphatic or aliphatic aromatic polyester selected in the list comprising Polylactic acid (PLA), Polyhydroxy alkanoate (PHA), Polybutylene succinate (PBS), Polybutylene succinate- co-adipate (PBSA), Polybutylene adipate-co-terephthalate (PBAT), Polybutylene sebacate-co-terephthalate (PBSeT), and their respective copolymers, and combination thereof; and/or wherein the filter layer (310) has a grammage between 10 and 150 g/m2, preferably between 20 and 100 g/m2.
9. The capsule (100) according to any one of the preceding claims, wherein the carrier layer (320) is made of a material that is compostable and has a defined closed fiber structure with at least 50% of weight corresponding to cellulose fibers comprising paper, soft wood, hard wood, or non-woody, materials and combination thereof and/or wherein the carrier layer (320) has a grammage between 20 and 150 g/m2, preferably between 30 and 100 g/m2.
10. The capsule (100) according to any one of the preceding claims, wherein the barrier layer (340) provides a, preferably bidirectional, barrier against moisture and/or oxygen, wherein the barrier layer (340) is made of a biodegradable, preferably, compostable material, comprising Polyglycolic acid (PGA), Polyvinyl alcohol (PVOH), Butanediol vinyl alcohol co-polymer (BVOH ) or any vinyl alcohol co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above mentioned materials, and wherein the barrier layer (340) is preferably made of a different material than the filter layer (310) and/or the carrier layer (320).
11. The capsule (100) according to any one of the preceding claims, wherein the barrier layer (340) is applied in one or more layers in a total quantity of 2 to 50 gsm (g/m2), preferably of 5 to 40 gsm (g/m2) on the surface of carrier layer facing the chamber (250).
12. The capsule (100) according to claim 11, wherein the Oxygen Transmission Rate (OTR) of the delivery wall (300) is below 35 cc/m2/day, preferably below 10 cc/m2/day, most preferably below 1 cc/m2/day measured according to ASTM D3985/ISO 15105 method.
13. The capsule (100) according to any one of the preceding claims, wherein the protective layer (350) is applied directly on the barrier layer (340) and is applied in one or more protective layers in a total amount of 5 to 30 gsm (g/m2), preferably between 5 and 20 gsm (g/m2) and with a maximum total thickness of 20 microns.
14. The capsule (100) according to claim 13, wherein the protective layer (350) is made of a biodegradable and preferably compostable material and is preferably non hydrosoluble, such as vegetable starch-based, protein-based, natural rubber-based adhesive, aqueous dispersion of polyester and/or polyurethane elastomer or acrylic polymers and copolymer and/or combination thereof.
15. The capsule (100) according to any one of the preceding claims, wherein the injection wall (210) is integral with the capsule body (200) and the capsule body (200) is made of cellulose-based pulp-molded material, preferably wood-based pulp-molded material.
16. System for preparing a beverage comprising a capsule (100) according to anyone of claims 1 to 15 and a beverage production machine with a fluid dispensing device capable of feeding the capsule with an amount of a fluid, such as water, with a pressure between 2 bars and 20 bars at the injection wall (210) of the capsule (100), and with a brewing chamber, comprising a first part for hosting the capsule, defined as the capsule holder, and a second part for closing the brewing chamber, wherein the second part of the brewing chamber comprises an opening structure for engaging with the delivery wall (300) of capsule (100) when the brewing chamber holding the capsule is closed, the opening structure comprising a relief and recessed surface facing, in use, the delivery wall (300), preferably the filter layer (310) of the capsule, wherein the delivery wall (300) of the capsule, in use in the closed brewing chamber, is opened with reduced tearing by the relief and recessed surface of the opening structure, when compared with a capsule comprising an aluminium delivery wall.
17. Use of a capsule (100) according to any one of the preceding claims 1 to 15, in a system for preparing a beverage according to claim 16, for preparing a beverage in a beverage production machine having a capsule holder.
PCT/EP2025/057308 2024-03-20 2025-03-18 Compostable top lid structure for a beverage preparation capsule Pending WO2025196014A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EPPCT/EP2024/057507 2024-03-20
EP2024057507 2024-03-20

Publications (1)

Publication Number Publication Date
WO2025196014A1 true WO2025196014A1 (en) 2025-09-25

Family

ID=90482596

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2025/057308 Pending WO2025196014A1 (en) 2024-03-20 2025-03-18 Compostable top lid structure for a beverage preparation capsule

Country Status (1)

Country Link
WO (1) WO2025196014A1 (en)

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0512470A1 (en) 1991-05-08 1992-11-11 Societe Des Produits Nestle S.A. Method of producing beverages using sealed cartridges and apparatus for carrying out this method
EP0512468A1 (en) 1991-05-10 1992-11-11 Societe Des Produits Nestle S.A. Closed cartridge for making a beverage
EP1165398A1 (en) 1999-03-18 2002-01-02 Societe Des Produits Nestle S.A. Sealed cartridge for making a beverage
EP1646305A1 (en) 2003-07-10 2006-04-19 Nestec S.A. Device for the extraction of a cartridge
EP1654966A1 (en) 2004-10-25 2006-05-10 Nestec S.A. Capsule with sealing means
EP2142054A1 (en) 2008-03-20 2010-01-13 Nestec S.A. Beverage production device for producing a beverage from a single-use capsule
JP2019517959A (en) * 2016-04-29 2019-06-27 アフルストロム−ムンクショー・オーイーユィ Compostable lid for sealing a capsule and the capsule sealed with the lid
WO2021145764A1 (en) 2020-01-17 2021-07-22 Huhtamaki Molded Fiber Technology B.V. Biodegradable packaging unit for a food product and method for manufacturing such packaging unit
EP3362377B1 (en) * 2015-10-13 2022-12-07 Advanced Technology Assets B.V. Capsule and device for preparing beverages and method for manufacturing a capsule
EP4072974B1 (en) * 2020-09-11 2023-03-22 Société des Produits Nestlé S.A. Compostable top lid structure for a beverage preparation capsule
WO2023052352A1 (en) 2021-09-30 2023-04-06 Société des Produits Nestlé S.A. Beverage or foodstuff container and preparation system
WO2023051967A1 (en) 2021-09-30 2023-04-06 Societe Des Produits Nestle S.A. Beverage or foodstuff preparation system
CA3233775A1 (en) * 2021-10-15 2023-04-20 Societe Des Produits Nestle S.A. A beverage capsule comprising a barrier liner attached to a pulp body

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0512470A1 (en) 1991-05-08 1992-11-11 Societe Des Produits Nestle S.A. Method of producing beverages using sealed cartridges and apparatus for carrying out this method
EP0512468A1 (en) 1991-05-10 1992-11-11 Societe Des Produits Nestle S.A. Closed cartridge for making a beverage
EP1165398A1 (en) 1999-03-18 2002-01-02 Societe Des Produits Nestle S.A. Sealed cartridge for making a beverage
EP1646305A1 (en) 2003-07-10 2006-04-19 Nestec S.A. Device for the extraction of a cartridge
EP1654966A1 (en) 2004-10-25 2006-05-10 Nestec S.A. Capsule with sealing means
EP2142054A1 (en) 2008-03-20 2010-01-13 Nestec S.A. Beverage production device for producing a beverage from a single-use capsule
EP3362377B1 (en) * 2015-10-13 2022-12-07 Advanced Technology Assets B.V. Capsule and device for preparing beverages and method for manufacturing a capsule
JP2019517959A (en) * 2016-04-29 2019-06-27 アフルストロム−ムンクショー・オーイーユィ Compostable lid for sealing a capsule and the capsule sealed with the lid
WO2021145764A1 (en) 2020-01-17 2021-07-22 Huhtamaki Molded Fiber Technology B.V. Biodegradable packaging unit for a food product and method for manufacturing such packaging unit
EP4072974B1 (en) * 2020-09-11 2023-03-22 Société des Produits Nestlé S.A. Compostable top lid structure for a beverage preparation capsule
WO2023052352A1 (en) 2021-09-30 2023-04-06 Société des Produits Nestlé S.A. Beverage or foodstuff container and preparation system
WO2023051967A1 (en) 2021-09-30 2023-04-06 Societe Des Produits Nestle S.A. Beverage or foodstuff preparation system
CA3233775A1 (en) * 2021-10-15 2023-04-20 Societe Des Produits Nestle S.A. A beverage capsule comprising a barrier liner attached to a pulp body

Similar Documents

Publication Publication Date Title
EP4072974B1 (en) Compostable top lid structure for a beverage preparation capsule
WO2024194163A1 (en) Compostable top lid structure for a beverage preparation capsule
EP4683866A1 (en) Compostable top lid structure for a beverage preparation capsule
WO2025026960A1 (en) Capsule for the preparation of a beverage
WO2025196014A1 (en) Compostable top lid structure for a beverage preparation capsule
WO2024194162A1 (en) Compostable top lid structure for a beverage preparation capsule
AU2024361842A1 (en) Capsule compostable top lid structure, sheet material for making the same and method
CN122003327A (en) The structure of the top cap of compostable capsules, the sheet material and method for manufacturing them
WO2025149496A1 (en) Compostable top lid structure for a beverage preparation capsule
IL323453A (en) Beverage extraction system
EP4683865A1 (en) Capsule for the preparation of a beverage
AU2024316802A1 (en) Capsule for the preparation of a beverage
WO2025103915A1 (en) Manufacturing process and manufacturing line for manufacturing an engraved cellulose-based container
AU2024382298A1 (en) Manufacturing process and manufacturing line for manufacturing an engraved cellulose-based container
CN122003375A (en) Capsules for preparing beverages

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 25712949

Country of ref document: EP

Kind code of ref document: A1