CN117693473A - Systems and methods for forming compostable pouches for beverages from sheets with controlled moisture content - Google Patents
Systems and methods for forming compostable pouches for beverages from sheets with controlled moisture content Download PDFInfo
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- CN117693473A CN117693473A CN202280051801.3A CN202280051801A CN117693473A CN 117693473 A CN117693473 A CN 117693473A CN 202280051801 A CN202280051801 A CN 202280051801A CN 117693473 A CN117693473 A CN 117693473A
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Abstract
本发明涉及用于制备用于冲煮产品的可堆肥囊囊包(900)的系统(100)。其中，囊包(900)用由可生物降解的纤维素基材料制成的片材(600)制成。系统(100)包括至少一条成形线(200)，该至少一条成形线包括用于沿着传送方向(TD)传送片材(600)通过系统(100)的操纵单元(300)。成形线(200)还包括加湿单元(400)，该加湿单元用于使用湿润剂(401)来湿润片材(600)的至少一侧，和成形单元(800)，该成形单元用于将所湿润片材(600)的一部分成形为三维形状，以形成限定囊包腔(911)的囊包元件(910)。成形线(200)还包括湿度传感器系统(500)，该湿度传感器系统用于视觉感测所湿润片材(600)的至少一个区段的湿度水平。与由湿度传感器系统(500)感测到的湿度水平相关的值由控制单元(700)接收，该控制单元被进一步配置为基于这些值来控制加湿单元(400)。本发明还涉及用于制备可堆肥囊包(900)的方法，由此视觉感测和转发所湿润片材(600)的至少一个区段的湿度水平，以用于对应地控制片材(600)的至少一侧的湿润过程。
The present invention relates to a system (100) for preparing compostable capsules (900) for brewing products. Wherein, the capsule (900) is made of a sheet (600) made of biodegradable cellulose-based material. The system (100) includes at least one forming line (200) including a handling unit (300) for conveying the sheet (600) through the system (100) in the transport direction (TD). The forming line (200) also includes a humidification unit (400) for moistening at least one side of the sheet (600) using a wetting agent (401), and a forming unit (800) for converting the A portion of the wet sheet (600) is formed into a three-dimensional shape to form a capsule element (910) defining a capsule cavity (911). The forming line (200) also includes a moisture sensor system (500) for visually sensing the moisture level of at least one section of the wetted sheet (600). Values related to the humidity level sensed by the humidity sensor system (500) are received by the control unit (700), which is further configured to control the humidification unit (400) based on these values. The invention also relates to a method for preparing a compostable sachet (900) whereby the moisture level of at least one section of a moistened sheet (600) is visually sensed and forwarded for corresponding control of the sheet (600) ) at least one side of the wetting process.
Description
1. Technical field
The present invention relates to a system and method for preparing a compostable sachet for use in a brew product, wherein the sachet is prepared from a sheet of biodegradable cellulose-based material.
2. Background art
Single serving beverage containers such as capsules or sachets for beverage preparation machines are known in the art. These beverage containers are commonly used for on-demand dispensing of beverages such as coffee, tea or hot chocolate and are popular due to the variability of fresh taste, flavor and convenience of beverage preparation.
Typically, these known beverage containers are made of materials for which repeated use, recycling or composting is challenging, particularly after use of the beverage container. As a result, biodegradable or compostable materials (such as cellulose-based materials, e.g., paper) are being used in place of these established materials, for which the process of disposing of used beverage containers (e.g., via composting) is less challenging.
The use of new materials for beverage containers also requires new manufacturing processes. For example, in industrial production, beverage containers made from cellulose-based materials may be produced from endless (continuous) sheets of paper material that travel through different stations of a production line. At one station, a section of sheet material is formed into a half-shell and then filled with a beverage component, such as coffee, before being sealed closed with another half-shell or lid.
Among other things, it has been found that wetting the sheet material prior to forming the half-shells can be beneficial to the structural integrity and shelf life of the resulting beverage container. For example, by wetting before the shaping step, tearing, wrinkling or nicking in the half-shell during the shaping process can be avoided. Examples of preparation processes with such a wetting process can be found in WO 2020/031096 A1.
In addition, it has been found that the quality of the result of the forming process depends on the local distribution and the amount of liquid absorbed by the sheet material. For example, high absorption of liquid by the sheet material may increase the risk of tearing or wrinkling of the sheet during the forming process or while being conveyed through the production line. Similarly, low absorption of liquid by the sheet material may increase the risk of half-shells breaking during the forming process. Thus, the integrity of the beverage container cannot be ensured, limiting the shelf life of the product within the beverage container.
In the prior art, these problems are solved by providing sensor systems along the production line, which are able to evaluate the extent of the moisture content contained in the sheet material. For example, known solutions rely on sensor technology based on the microwave radiography method or absorption of infrared radiation, the latter taking advantage of the fact that water absorbs mainly infrared radiation while being transparent to most other components of light in the visible spectrum. Other known sensor solutions for determining the extent of moisture content contained within a sheet material may be destructive or may require a sensor probe to physically contact the sheet material (e.g., a gravity sensor or a resistance sensor).
A disadvantage of the known sensor system is that the measurement results are very localized and, therefore, the determination of the moisture content within the sheet material can only be established for small localized sections of the sheet material. Therefore, a local change in the moisture content of the entire sheet cannot be detected. Furthermore, the measurement accuracy of known sensor systems is often too low for the requirements of the manufacturing process, since these systems are more affected by radiation noise in the surrounding environment. Further, during the preparation of beverage containers, the sheet material travels through the production line at a speed that makes it difficult to take advantage of all the benefits of infrared or microwave technology. In contrast, infrared sensor systems are commonly used in static applications, such as construction sites for determining the moisture content in bricks or floors, and the measurement accuracy is fixed, mainly depending on the object of interest. Furthermore, the movement of the sheet through the production line makes it difficult to distribute the measurement results to the respective sections of sheet material with sufficient accuracy. Thus, due to such misalignment, the measured section of the sheet may not be as great or relevant to the forming process. Another disadvantage of the known sensor system is that there is a delay between taking the measurement and determining the extent of the moisture content contained in the sheet material. Therefore, it may be necessary to reduce the conveyance speed of the sheet to reduce the lag time and synchronize the measurement process with the manufacturing process. Furthermore, methods that require direct contact between the sensor probe and the sheet or that must destructively analyze samples cut from the sheet are generally considered unsuitable for industrial scale production.
Thus, due to the above-described problems surrounding measuring the moisture content within the sheet material, it is difficult to achieve accurate and optimal control of the wetting process. As a result, the risk of the structural integrity of the beverage container being compromised during the forming step increases because the moisture content at the forming step cannot be accurately monitored and set. Thus, the shelf life and quality of the beverage containers so produced cannot be ensured.
It is therefore an object of the present invention to provide a system and method for preparing sachets made of compostable materials wherein the structural integrity and shelf life of the produced sachets can be improved and ensured. Among others, it is a particular object of the invention to improve the speed, accuracy and reliability of measuring the moisture content of any liquid contained in a sheet material, as well as to improve the control of the wetting step in the manufacturing system and process.
These and other objects, which will become apparent after a reading of the description, are solved by the subject matter of the independent claims. The dependent claims relate to preferred embodiments of the invention.
3. Summary of the invention
A first aspect of the invention relates to a system for preparing a compostable sachet for use in brewing products. The system is adapted or configured for preparing the sachet from a sheet of biodegradable cellulose-based material.
Wherein the term "sachet" may be understood as any (closed) container (e.g. capsule) for preparing a beverage in a beverage production machine, for example. For example, beverage preparation may include dissolving, brewing or percolating a substance enclosed within a sachet to produce a brewed product, such as coffee or tea.
The term "sheet" may be understood as, for example, a large, thin, flat piece of material.
For example, the sheet may be supplied in a dry state, i.e. with a maximum level of (relative) moisture or humidity in the range of 2% to 8%, preferably 4% or 5%.
Furthermore, the term "compostable" may be understood to mean that when the material is composted it may substantially break down into organic matter within weeks or months. This may be done in an industrial composting site and/or in a home composter. Specific conditions associated with wind, sunlight, water drainage and other factors may exist at these sites. At the end of the composting process, once the material has completely decomposed, the land may be supplied with nutrients. International standards (such as EU 13432 or US ASTM D6400) provide a legal framework for specifying technical requirements and procedures for determining the compostability of materials. In contrast, "biodegradable" materials can be understood as any material that can be decomposed into environmentally benign products by (the action of) organisms, such as microorganisms, e.g. bacteria, fungi or algae. The process may be performed in an environment with or without oxygen (aerobic/anaerobic).
The system comprises at least one forming line comprising a handling unit for conveying the sheet through the system in a conveying direction. The forming wire also includes a humidifying unit for humidifying at least one side of the sheet using a humidifying agent.
Wherein the term "humidifying unit" may be understood as a component of, for example, a forming wire, which can be (or is configured to) be used to bring (apply or introduce) a wetting agent (liquid, solution) into or onto the sheet. For this purpose, the wetting agent may be applied directly to the sheet or the carrier medium (e.g. ambient air) may be wetted or moistened by a humidifying unit, which may transfer moisture to the sheet.
The shaping line includes a shaping unit for shaping a portion of the wetted sheet material into a three-dimensional shape to form a bladder element defining a bladder cavity.
Wherein the term "forming" may be understood as changing its (three-dimensional) shape (with or without support of additional tools and/or preferably with or without application of heat), e.g. by taking advantage of the formability, ductility and/or flexibility of the material. Furthermore, the term "wet" may be understood as, for example, a sheet material being subjected to a wetting agent and the wetting agent being present in the material. Preferably, the wetted sheet material carries a quantity of wetting agent.
The at least one forming line further includes a humidity sensor system for visually sensing a humidity level of at least one section of the wetted sheet. Preferably, the section may correspond at least in part to the part to be formed.
Wherein the expression "visual sensing" can be understood as sensing similar to the human eye. For example, it may be understood as optical sensing, i.e. sensing based on information carried by light in the visible spectrum. The humidity sensor system may be adapted (configured) for capturing at least a two-dimensional (optical, visual) image by means of which the light intensity distribution (for a defined wavelength) may be detected.
Furthermore, the expression "humidity level" (moisture content) may be understood as a numerical quantification of, for example, the main liquid substance (or moisture and/or humidity) contained within the sheet material. For example, it is conceivable that the humidity level may be an indication of the water content (liquid and/or gaseous) in the paper and/or the relative humidity of the (paper) sheet material. Where water content (or moisture content) may be understood as the amount of (liquid and/or gaseous) water (e.g. measured by weight in grams) contained in a solid material, for example. It is thus clear that in this specification the terms "moisture" and "humidity" are used interchangeably unless explicitly stated otherwise.
For example, the humidity level (moisture content) may be expressed as absolute humidity. For example, the liquid (humectant) content of the material may be measured in weight/volume (g/m 3 ) And (5) measuring. Alternatively or additionally, the humidity level (moisture content) may be expressed as relative humidity. For example, the liquid content may be measured as a ratio (e.g., a ratio expressed as a percentage) between the measured humectant content and the maximum amount of liquid content that is absorbable in the material.
The at least one shaping line further comprises a control unit configured to receive values related to the humidity level sensed by the humidity sensor system and to control the humidifying unit based on these values.
In other words: according to an arrangement of the present invention, a preparation system may be provided which is capable of producing compostable sachets for a brewing product from a cellulose based sheet material. To this end, the system comprises a forming line capable of (sequentially) performing various functions or operations involved in the bag production (preparation) process, which are interconnected so that a compostable bag with reliable and high structural integrity can be achieved. For example, a handling unit is provided which is adapted to (linearly) transport (carry, move, drag, transport) sheets through the system. Furthermore, a humidifying unit is provided for applying a (liquid and/or gaseous) wetting agent to at least one side of the sheet. Wherein, for example, the wetting agent may be any substance or liquid, such as water, distilled water, or any aqueous solution, which may preferably be adapted to reduce the inherent stiffness of the sheet material of the sachet used in the forming step. The forming process of the bag element (or of the bag body or of at least a part of the bag) is thereby supported, since in the forming unit the forming process can be performed on wet sections of the sheet material, which is beneficial in avoiding the damage to the bag integrity caused by the forming process. The forming wire also includes a humidity sensor system. From this, the amount, location, and degree of wetting agent within the sheet can be determined. Among other things, visual sensing facilitates short measurement times, measurement of defined areas, and the ability of light to enter deep within the sheet material. Thus, the size of the measuring area, the measuring speed and the measuring accuracy can be improved compared to the sensor methods known in the prior art. This allows the control unit to adjust the humidification process in the humidification unit faster, more accurately and less dependent on highly localized measurements. The control unit is configured to evaluate values related to the humidity level, which may be raw values (e.g. intensity values of light of a specific wavelength), calculated values, converted values or weighted values determined by the sensor, or which may have been the final result of an analysis of the measured values by the humidity sensor system. Since the accuracy, speed and quality of the information contained in the values can be improved, the control of the humidification process can be done more accurately, more timely and adapted to the transient situation than in prior art solutions. In particular, the manufacturing process may be monitored and controlled in real-time (i.e., the response of the system may be guaranteed to be within certain time limits, such as reacting within half of the time required for a sheet segment to travel between two successive stations).
Thus, sachets made of compostable materials can be prepared wherein the structural integrity and shelf life of the produced sachets are improved and ensured. The system of the present invention thus overcomes the disadvantages of the prior art.
According to a preferred embodiment, the humidity sensor system may include an optical instrument to capture a visual image of at least the section of the wetted sheet. The visual image may represent a humidity level. For example, the optical instrument may be a (high resolution) camera. Preferably, the resolution of the optical camera may be in the range of 500 to 2000 ten thousand pixels, preferably 1200 ten thousand pixels. The visual image may comprise a plurality of pixels. Preferably, each of the received (humidity level dependent) values may be associated with one or more pixels. Preferably, the visual image may have a resolution of at least 100 Pixels Per Inch (PPI), preferably at least 300PPI, more preferably about 900PPI (or, differently expressed as 30 microns per pixel).
Thereby, a section of the sheet may be scanned in at least two dimensions with high resolution, such that an accurate representation of the amount and quality of the moisture distribution in the sheet may be determined. Thus, the wetting process may be made closer to the requirements of the forming process due to the improved quality and information value of the acquired measurement data.
According to a preferred embodiment, the humidity sensor system may comprise at least one light source. For example, the light source may be an LED light source for emitting light of one or more defined wavelengths within the visible spectrum.
Wherein the expression "visible spectrum of light" may be understood as light having a wavelength between 380 nm (e.g. violet) and 700 nm (e.g. red), preferably between 380 nm and 900 nm (e.g. near infrared).
Preferably, the light source may be arranged such that the emitted light is directed onto at least the section of the wet sheet material so as to be reflected. For example, the light source may be arranged such that the emitted light may be reflected towards the optical instrument to capture the reflected light as a visual image.
Thus, a humidity sensor system may be provided with an active light source by which defined light may be emitted and the response (e.g. absorbance, reflectivity, phase shift) between the emitted light and the liquid contained in the section of material to be measured may be recorded. With this configuration, the effect of radiation noise on measurement accuracy and effectiveness can be reduced or even eliminated. In addition, by emitting light of various different wavelengths, the reflected intensity of the material of different wavelengths can be detected. This allows the moisture content of various humectant compositions to be detected. For example, the wetting agent may comprise a surfactant or ingredient that may cause the sheeting material to have a different reflected intensity at a particular wavelength of light than the sheeting material wetted with water alone. Furthermore, reflectance profiles or features may be created for the observed segments, which may be compared to reference features for various moisture content (within the same material). Thus, the system can be adapted to the respective application and allows the use of different humectants. Among other things, it is also contemplated that the wetting agent may comprise a substance that further improves the accuracy of the reflectance or absorbance measurement by responding in a particular manner to a particular wavelength of the emitted light.
According to further preferred embodiments, the humidity sensor system may be arranged above the section of the sheet or wetted sheet to be visually sensed. For example, at least the optical instrument (if present) may be arranged in this way. Where "above" may be understood as, for example, perpendicular to the sheet surface and/or the conveying direction (e.g., relative to gravity).
Thereby, data can be acquired from the relevant sections of the sheet in an advantageous manner.
According to a preferred embodiment, the humidity sensor system may be positioned downstream of the humidifying unit with respect to the conveying direction, and preferably upstream of the shaping unit. For example, at least the optical instrument may be arranged in this way.
Thereby, the result of the wetting step can be (immediately) determined and the wetting process is adjusted based on the data thus obtained.
According to a further preferred embodiment, the control unit may be configured to compare the received (humidity level dependent) value with a defined reference value. Alternatively or additionally, the control unit may be configured to control the humidification unit based on a comparison between the received (humidity level dependent) value and the defined reference value.
From this, any difference between the desired moisture content and the actual (measured) moisture content in the sheet material may be determined. For example, statistical or machine learning methods, such as Principal Component Analysis (PCA), may be applied.
According to a preferred embodiment, the system or control unit may comprise a data storage unit for storing the defined reference values. Alternatively or additionally, the system or control unit may comprise a communication port for retrieving the defined reference value and/or the received (humidity level dependent) value.
Thus, a connection to a data network (e.g., the Internet) or database may be provided for the system for storing, analyzing and evaluating the acquired data and the adjusted control settings. This is advantageous for continuously improving the control algorithm used at the control unit and all operations performed within the system.
According to a further preferred embodiment, the humidifying unit may be arranged to wet only one side of the sheet. For example, the humidifying unit may be arranged to only wet the underside of the sheet as it is conveyed horizontally (e.g. with respect to gravity) through the humidifying unit. Preferably, the humidifying unit may be arranged on the side of the sheet opposite to the humidity sensor system. Preferably, the humidifying unit may comprise a scraper element for removing excess liquid from the sheet, which scraper element may preferably be arranged at a downstream end section of the humidifying unit with respect to the conveying direction.
Thereby, the risk of water droplets falling into the sensing part of the humidity sensor system and thus changing the accuracy and effectiveness of the measurement may be reduced. Further, by applying the wetting agent on the side of the sheet opposite to the position of the sensor, it is ensured that the wetting agent is sufficiently immersed in the sheet material, thereby improving the reliability of measurement and reducing the risk of measuring data outliers caused by local variations in the liquid concentration caused by the wetting process in the wetting unit.
According to a preferred embodiment, the humidifying unit may comprise an immersing unit for immersing at least one side of the sheet in the humidifying agent. Alternatively or additionally, the humidifying unit may comprise a spraying unit for spraying the humidifying agent onto at least one side of the sheet. Alternatively or additionally, the humidifying unit may comprise a steam unit, preferably a cold steam unit, for applying a humectant to at least one side of the sheet. Alternatively or additionally, the moistening unit may comprise a roller transfer unit for transferring the moistening agent from the reservoir onto at least one side of the sheet.
Thus, the wetting agent may be applied to the sheet material in a variety of ways.
According to a further preferred embodiment, the system may further comprise a pre-drying unit for drying the sheet before it reaches the forming unit. Preferably, the pre-drying unit may be adapted and/or configured for drying at least a portion (on at least one side) of the sheet. Preferably, the control unit may be further configured to control the pre-drying unit based on these values. Alternatively or additionally, the system may further comprise a final drying unit for drying the sachet element. Preferably, the bag element may be a formed (part of) sheet. The control unit may be further configured to control the final drying unit based on these values.
Thereby, the moisture content contained in the wet section of the sheet can be reduced before reaching the forming unit. Wherein the control of the pre-drying unit may be adjusted based on the measurement result done by the humidity sensor system. Hereby it is ensured that the wet section of the sheet can be formed in a forming unit with an optimal moisture content.
According to a preferred embodiment, the system may further comprise a filling unit for placing a quantity of brewing material in the capsule cavity of the capsule element. For example, the filling unit may be arranged downstream of the final drying unit with respect to the conveying direction.
Wherein the brewing material may be a substance such as any type of (solid semi-solid or gelatinous, at least partially soluble and/or diafiltered) substance of a specific or defined chemical composition. Examples of such substances may be roast and ground coffee, instant coffee, tea, chocolate products, dehydrated edible substances and/or combinations thereof.
Thereby, the sachet element may be dried before reaching the filling unit, so that the sachet is filled in a dry state, which is beneficial for the shelf life of the resulting sachet.
According to a further preferred embodiment, the system may further comprise an engagement unit for engaging the closure element to the sachet element to close the sachet cavity, preferably around a quantity of brewing material. For example, the closure element may be a cap or another sachet element. Preferably, the bag elements are joined such that their cavities together form a closed bag cavity. To this end, the system may comprise two forming lines, each forming line being for forming one bag element, and the joining unit being for joining the two bag elements to form a bag cavity.
Thereby, a physical (and preferably sealed) connection may be provided between the sachet element and the corresponding closure element. The connection may be achieved by heat sealing or ultrasonic sealing. Thus, an airtight closure or encapsulation of the brewing material may be provided within the sachet cavity. Thereby, the integrity and shelf life of the sachet can be ensured.
According to a further preferred embodiment, the sheet may be an endless sheet. The sheet may preferably be supplied from a reel. To this end, for example, the system may further comprise a conveying unit for unwinding the sheet.
Thus, the sheet material may be provided in a manner particularly suitable for industrial production. In particular, sequential processing at different stations is improved by providing the sheet as a continuous sheet. For example, the sheet material may extend longitudinally in a continuous manner. In particular, the sheet may be adapted to be joined with other such sheets at end sections to form a sheet that appears "endless" in the manufacturing process.
According to a preferred embodiment, the sheet may have gas barrier properties.
Among other things, gas barrier can be understood as the ability to reduce or eliminate gaseous substances passing through the sheet material, for example. For example, the sheet may have an Oxygen Transmission Rate (OTR) of less than 5cm 3 /m 2 Oxygen barrier layer per day. However, OTR values may depend on the characteristics of the material used for the sheet. In general, OTR may be a measure of the amount of oxygen that passes through a substance over a defined period of time. For example, OTR may be measured using known methods specified in industry standards, such as DIN 53380-3, ASTM D1434, or ISO 2872.
In this regard, it is noted that the application of too much wetting agent to the sheet material can result in a decrease in the effectiveness of the oxygen barrier (and thus an increase in OTR) due to, for example, irreversible swelling of the fibers in the sheet material. Thus, the humidity sensor system may preferably be arranged such that the moisture content may be sensed before the oxygen barrier may be irreversibly damaged or altered.
The sheet may have a single-layer structure made of a cellulose-based material having gas barrier properties. Alternatively, it is also conceivable that the sheet may have a multilayer structure including a paper layer made of a cellulose-based material and a barrier layer having gas barrier properties. Preferably, the paper layer may form at least one side of the sheet and/or the above-mentioned lower side.
By providing a sheet with a gas barrier, the shelf life of the sachet can be increased.
Further aspects of the invention relate to methods for preparing a compostable sachet configured and/or adapted for use in brewing products. The method comprises the step of conveying a sheet made of biodegradable cellulose-based material through the system described above in a conveying direction. For example, the biodegradable cellulose-based material may preferably have gas barrier properties. At least one side of the sheet is moistened with a humectant. A portion of the wetted sheet is formed into a three-dimensional shape to form a bladder element defining a bladder cavity. Preferably, the sachet element may be dried. The method further includes the step of visually sensing the moisture level of at least one section of the wetted sheet. A value related to the sensed humidity level is received. Based on these values, wetting (step, process, result or effect) of at least one side of the sheet is controlled.
All the definitions and effects described above for the system apply equally to the method of the invention. The system is adapted to perform the method of the invention.
According to the configuration of the method of the present invention, a compostable sachet having high and reliable structural integrity and shelf life can be provided from sheet material. This is possible because the method allows measuring and adjusting the liquid content in the sheet so that the shaping of the sheet into a sachet can be improved.
According to a preferred embodiment, the step of visually sensing may comprise capturing a visual image of at least the section of the wetted sheet material, the visual image representing (displaying or indicating) the humidity level. Alternatively or additionally, the step of visually sensing may comprise the steps of: emitting light of one or more defined wavelengths within the visible spectrum onto at least that section of the wetted sheet; and captures the reflected light as a visual image.
Thereby, the accuracy and reliability of the acquired data related to the moisture content can be improved, while the measurement time can be reduced. In particular, the manufacturing process may be monitored in real time.
According to further preferred embodiments, the step of controlling wetting (step, process, result or effect) may comprise the steps of: comparing the received (humidity level dependent) value with a defined reference value; and controlling (e.g., adjusting) the wetting based on a comparison between the received (humidity level related) value and the defined reference value.
Thereby, the control of the moisture content can be improved. In particular, the manufacturing process can be controlled in real time due to the measurement.
According to a preferred embodiment, the method may further comprise the step of placing a quantity of brewing material in the cavity of the capsule element. Alternatively or additionally, the method may further comprise the step of joining a closure element to the sachet element to close the cavity. Wherein the step of engaging may preferably comprise the step of engaging a cap as the closure element. Alternatively, the step of joining may preferably comprise the step of joining a further sachet element as the closure element, wherein preferably the sachet elements may be joined such that their cavities together form a closed sachet cavity.
Thus, a sachet with beverage ingredients can be provided and sealed from the outside. Thus, the sachet may have a relatively long shelf life.
4. Description of the drawings
Additional features, advantages and objects of the invention will become apparent to those skilled in the art upon reading the following detailed description of embodiments of the invention in conjunction with the accompanying drawings. Where numerals are omitted from the figures, for example, for clarity, corresponding features may still be present in the figures.
Fig. 1 shows a schematic side view of a shaping line of a sachet preparation system according to an embodiment of the invention.
Fig. 2 shows a schematic top view of the forming line and system of fig. 1.
Fig. 3 shows a schematic cross-sectional side view of a sachet prepared using a system and method according to a further embodiment of the present invention.
Fig. 4 shows a schematic cross-sectional side view of a sachet prepared using a system and method according to a further embodiment of the present invention.
5. Detailed description of the preferred embodiments
Fig. 1 and 2 illustrate different views and aspects of embodiments of a system 100 and method for preparing a compostable sachet 900 for a brewed product in accordance with the present invention. Figures 3 and 4 illustrate aspects of different embodiments of a compostable sachet 900 made using the system 100 and method according to the present invention.
The system 100 is configured for preparing a compostable bag 900 from a sheet 600. Fig. 1 and 2 exemplarily illustrate a system 100 and some components. Fig. 3 and 4 illustrate examples of sachets 900 that can be produced using the system 100.
The sheet 600 is made of biodegradable cellulose-based material. For example, the cellulose-based material may include cellulose fibers, paper, cardboard, cellulose pulp for molding, cellulose nanofiber sheets or films, air laid cellulose, and/or delignified wood. For example, sheet 600 may be made of paper comprising (other) biodegradable materials. The material of sheet 600 may provide a barrier to moisture and/or gas. To this end, the sheet 600 may have a single layer structure of, for example, a cellulose-based material, which layer is sufficiently thick or configured to provide gas barrier properties. Fig. 1, 2 and 4 exemplarily illustrate the use of a sheet 600 having a single layer. Alternatively, the sheet 600 may have, for example, a multilayer structure having a paper layer 611 made of a cellulose-based material and a barrier layer 612 having gas barrier properties. Fig. 3 illustrates schematically the use of such a material configuration for sheet 600.
For purposes of industrially preparing the pod 900, the sheet 600 may be provided as, for example, an endless sheet. This type of sheet 600 may be provided from a reel, and the system 100 may include a conveying unit (not shown) for unwinding the sheet 600 from the reel and for introducing the sheet 600 into the system 100. However, it is also conceivable to provide the sheet 600 as a separate blank sheet. Preferably, the sheet 600 may have a thickness of between 50 microns and 200 microns, more preferably between 120 microns and 130 microns.
The system 100 includes at least one forming line 200. Fig. 1 and 2 exemplarily show an embodiment of a forming wire 200. For example, the forming line 200 may include a series of stations, each station providing the functions required to prepare the sachet 900. For example, sections of sheet 600 may pass through each station in sequential order. The system 100 may include one or more forming lines 200.
The forming line 200 includes a handling unit 300 for conveying the sheet 600 through the system 100 in a conveying direction TD. In fig. 1 and 2, the handling unit 300 is exemplarily shown as two rollers 461, 462, which may be arranged opposite to each other with respect to the sheet 600. However, it is also conceivable that the handling unit 300 may be provided by a conveyor belt, a pusher or a moving gripper. Furthermore, additional processing elements (e.g., rollers) of the handling unit 300 may be provided at various locations along the conveying direction TD to ensure continuous conveyance of the sheet 600 through the system 100. Preferably, the sheet 600 is linearly movable along the conveyance direction TD. The sheet 600 may be transported horizontally (as exemplarily shown in fig. 1 and 2) or vertically (not shown) within the system 100.
The forming line 200 further comprises a humidifying unit 400 for humidifying at least one side of the sheet 600 using a humidifying agent 401. Fig. 1 and 2 illustrate an exemplary embodiment of a humidifying unit 400.
As shown in fig. 1 and 2, the humidifying unit 400 may include a roller conveying unit 410 for conveying the humidifying agent 401 from the reservoir 411 onto at least one side of the sheet 600. For example, the wetting agent 401 may be applied to the underside 601 of the sheet 600 by a roller 461, wherein preferably the roller 461 may be at least partially immersed in the wetting agent 401. The roller 461 may then contact the sheet 600 and thereby may bring the wetting agent 401 into the sheet material within a defined section of the sheet 600, which may be referred to as a wetting section 640 (fig. 2) of the sheet 600. For example, the moisture content in the wet section 640 may be higher than the moisture content in the remainder of the sheet 600 (e.g., the portion prior to the roller 461). Preferably, the humidifying unit 400 may be arranged to wet only one side of the sheet 600. This is exemplarily shown in fig. 1 and 2, wherein only the underside 601 of the sheet 600 is wettable by the humidifying unit 400. Thus, excess liquid may leave the underside 601 and may be returned to the reservoir 411. However, it is also contemplated that the upper side 602 and the lower side 601 of the sheet 600 may be wetted.
Further, other embodiments of the humidifying unit 400 are conceivable, which will be briefly discussed below: for example, the humidifying unit 400 may include an immersing unit for immersing at least one side of the sheet 600 into the wetting agent 401. Alternatively or additionally, the humidifying unit 400 may comprise a spraying unit for spraying the humidifying agent 401 onto at least one side of the sheet 600. Alternatively or additionally, the humidifying unit 400 may comprise a (cold) steam unit for applying a humidifying agent 401 onto at least one side of the sheet 600.
Preferably, the sheet 600 may be provided such that the barrier layer 612 may be disposed on opposite sides of the humidifying unit 400, for example, in order to facilitate sufficient absorption of the wetting agent 401 during the wetting process. In other words, the paper layer 611 may preferably be at least one side and/or the underside 601 of the sheet 600.
The wetting agent 401 may be, for example, (distilled) water or an aqueous solution.
The forming wire 200 also includes a forming unit 800 for forming a portion of the wetted sheet 600 into a three-dimensional shape to form a bladder element 910 defining a bladder cavity 911. Wherein, preferably, the wet section 640 of the sheet 600 may be the portion for forming and thus may be subjected to a forming process. Fig. 1 schematically shows an embodiment of a forming unit 800. In this example, the forming unit 800 may include a forming tool, such as a forming die 810 and a movable corresponding stamper 820, for forming the pod element 910 with the pod cavity 911.
For example, the body of the pod 900 may be formed from the pod element 910. As exemplarily shown in fig. 3 and 4, the pod element 910 may define a pod interior having a pod cavity 911.
The forming line 200 also includes a humidity sensor system 500 for visually sensing the humidity level of at least one section of the wet sheet 600. Fig. 1 and 2 schematically illustrate an embodiment of a humidity sensor system 500. Preferably, the humidity sensor system 500 may sense a humidity level at a section of the sheet 600, which may correspond at least in part to the part to be formed in the forming unit 800. This is illustrated schematically in fig. 1 and 2, whereby the humidity sensor system 500 (continuously in time and space) checks the wetting section 640.
For example, the humidity sensor system 500 can include an optical instrument 510, such as a (high resolution) camera, to capture a visual image of at least the section of the wetted sheet 600 that is representative of the humidity level. This is indicated exemplarily in fig. 1 and 2. The visual image thus captured may comprise a plurality of pixels. Each of the received (humidity level dependent) values may be associated with one or more pixels.
The humidity sensor system 500 can include a light source 520 for emitting light in the visible spectrum. For this purpose, a single light source 520 may be provided. Fig. 1 exemplarily shows that the humidity sensor system 500 can further include a plurality of LED light sources 521, 522, 523, 524, 525, each provided for emitting light of one or more defined wavelengths within the visible spectrum. For example, wavelengths around 380 nm, 450 nm, 520 nm, 590 nm, 660 nm, and/or 700 nm may be used. Alternatively or additionally, the light source 520 (with one or more light sources) may emit light having a continuous spectrum within the visible spectrum (i.e., continuous scanning). The light source 520 may be arranged such that the emitted light 531 is directed onto at least the section of the wet sheet material 600 so as to be reflected towards the optical instrument 510 to capture the reflected light 532 as a visual image. This is shown schematically in fig. 1.
Preferably, the optical instrument 510 may be capable of acquiring data within a defined measurement window 560. This is illustrated schematically in fig. 1 and 2. Preferably, the measurement window 560 may have any shape or form. For example, the measurement window 560 may have a diameter between 2cm and 20 cm.
The humidity sensor system 500, or at least the optical instrument 510, may be arranged above the sheet 600 or a section of the wetted sheet 600 to be visually sensed. This is illustrated schematically in fig. 1 and 2. Alternatively or additionally, the humidity sensor system 500 or at least the optical instrument 510 may be positioned downstream of the humidifying unit 400 and preferably upstream of the shaping unit 800 with respect to the conveying direction TD. This is schematically shown in fig. 1 and 2. Preferably, the humidification unit 400 and the humidity sensor system 500 may be disposed on opposite sides with respect to the sheet 600. This is illustrated schematically in fig. 1 and 2.
The shaping line 200 further comprises a control unit 700 configured to receive values related to the humidity level sensed by the humidity sensor system 500 and to control the humidifying unit 400 based on these values. Wherein the control unit 700 may be configured to compare the received value with a defined reference value and to control the humidification unit 400 based on the comparison between the received value and the defined reference value.
For example, the sheet 600 may be considered to have a good moisture content, wherein the (relative) moisture content or humidity level of the sheet material is in the range of 9% to 40%, preferably 12% to 18%, and more preferably 12% to 16%. However, the present invention is not limited to these specific values, as they may vary according to the respective sheet materials.
Preferably, the control unit 700 may be configured to control and/or adjust a plurality of different parameters and components of the forming wire 200. For example, the control unit 700 may be configured to adjust the travel speed of the sheet 600, the composition of the wetting agent 401, the rotational speed of the rollers 461, 462, and/or the temperature of the forming tools 810, 820 provided in the forming unit 800. To this end, the system 100 or the control unit 700 may comprise a data storage unit 701 for storing defined reference values. Alternatively or additionally, the system 100 or the control unit 700 may comprise a communication port 702 for retrieving defined reference values and/or received values from an external source. The control unit 700 may preferably be connected with all elements of the shaping line 200, in particular with the handling unit 300, the humidifying unit 400, the shaping unit 800, the humidity sensor system 500 and/or other components described below. Information links (connections) between the respective components are schematically shown by arrows 730 and 570, which schematically indicate data connections between the control unit 700 and the manipulation unit 300 and between the control unit 700 and the humidity sensor system 500.
For example, the system 100 may also include a pre-drying unit for drying the sheet 600 before it reaches the forming unit 800. Preferably, at least the wet portion of the sheet 600 may be dried by a pre-drying unit. Alternatively or additionally, the system 100 may further comprise a final drying unit for drying the sachet element 910. Alternatively or additionally, the system 100 may further comprise a filling unit for placing a quantity 990 of brewing material in the pod cavity 911 of the pod element 910. Wherein for example the filling unit may be arranged downstream of the final drying unit with respect to the transport direction TD. However, it is also contemplated that the filling unit may be part of the forming unit 800. Alternatively or additionally, the system 100 may comprise an engagement unit for engaging the closing element 950 to the sachet element 910 to close the sachet cavity 911 around a quantity of brewing material 990.
Fig. 3 and 4 show different examples of embodiments of the closure element 950. For example, the closure element 950 may be a cover 951, such as that exemplarily shown in fig. 3. Alternatively, the closure element 950 may be another sachet element 910, wherein preferably the sachet elements are engageable such that their chambers 911 together form a closed sachet chamber 911. To this end, it is conceivable that the system 100 may be provided with two forming lines 200, each forming line for forming a bag element 910, and that the joining unit is provided for joining two bag elements 910.
Further aspects of the invention relate to methods for preparing a compostable sachet, such as the sachet 900 described above. Fig. 1 and 2 show the steps of the method.
For example, in this method, a sheet made of biodegradable cellulose-based material, and preferably possibly having gas barrier properties (such as the sheet 600 described above), is conveyed through the system 100 along the conveying direction TD.
At least one side of the sheet 600 is wetted with a wetting agent, such as wetting agent 401 described above.
The humidity level of at least one section of the wetted sheet 600 (such as wetted section 640) is visually sensed such that a value related to the sensed humidity level can be received. Wherein the step of visually sensing may comprise capturing a visual image of at least the section of the wetted sheet 600 representative of the humidity level. Alternatively, the step of visual sensing may comprise the steps of: emitting one or more defined wavelengths of light 531 within the visible spectrum onto at least that section of the wetted sheet 600; and captures the reflected light 532 as a visual image.
A portion of the wetted sheet 600 is shaped into a three-dimensional shape to form a bladder element defining a bladder cavity, such as the bladder element 910 described above with bladder cavity 911. It is conceivable to dry the bag member 910 after forming. However, the sachet element 910 can be dried at various other stages throughout the manufacturing process.
The wetting process of at least one side of the sheet 600 is controlled based on the value acquired in the visual sensing step (step). Wherein the step of controlling wetting may comprise comparing the received value with a defined reference value and controlling wetting based on the comparison between the received value and the defined reference value.
The method may further include the step of placing an amount of brewing material (such as brewing material 990 described above) in cavity 911 of the capsule element 910. The method may further include the step of engaging a closure element (such as closure element 950 described above) to the sachet element 910 to close the cavity 911. This is illustrated schematically in fig. 3 and 4. For example, the step of engaging may include engaging a cover 951 as the closure element 950 to the sachet element 910. Alternatively, another sachet member 910 can be engaged as the closure member 950. Thus, the bag elements 910 may be joined such that their chambers 911 together form a closed bag chamber 911 (one).
The invention is not limited by the embodiments described herein above, as long as it is encompassed by the appended claims. All features of the embodiments described above may be combined in any possible way and can be provided interchangeably.
Claims (15)
1. A system (100) for preparing a compostable sachet (900) for a brewing product from a sheet (600) made of biodegradable cellulose-based material, the system (100) comprising at least one forming line (200) comprising:
-a handling unit (300) for conveying the sheet (600) through the system (100) along a conveying direction (TD);
-a humidifying unit (400) for humidifying at least one side of the sheet (600) using a humidifying agent (401); and
-a forming unit (800) for forming a portion of the wetted sheet material (600) into a three-dimensional shape to form a sachet element (910) defining a sachet cavity (911);
wherein the at least one forming wire (200) further comprises:
-a humidity sensor system (500) for visually sensing a humidity level of at least one section of the wetted sheet (600), and
-a control unit (700) configured to receive values related to the humidity level sensed by the humidity sensor system (500) and to control the humidification unit (400) based on these values.
2. The system (100) according to claim 1, wherein the humidity sensor system (500) comprises an optical instrument (510), preferably a camera and more preferably a high resolution camera, to capture a visual image of at least the section of the wetted sheet (600) representative of the humidity level, wherein preferably the visual image comprises a plurality of pixels, wherein more preferably each of the received values is associated with one or more of the pixels.
3. The system (100) according to claim 1 or claim 2, wherein the humidity sensor system (500) comprises a light source (520), preferably an LED light source (521, 522, 523, 524, 525), for emitting light of one or more defined wavelengths within the visible spectrum, wherein the light source (520) is arranged such that the emitted light (531) is directed onto at least the section of the wetted sheet (600) so as to be reflected, preferably towards the optical instrument (510), if present, to capture reflected light (532) as the visual image.
4. The system (100) according to any one of the preceding claims, wherein the humidity sensor system (500), preferably the optical instrument (510), if present at least, is arranged on the opposite side of the humidification unit (400) with respect to the sheet (600) or the section of the wetted sheet (600) to be visually sensed, and/or
Wherein the humidity sensor system (500), preferably the optical instrument (510), if present at least, is positioned downstream of the humidifying unit (400) and preferably upstream of the shaping unit (800) with respect to the conveying direction (TD).
5. The system (100) according to any one of the preceding claims, wherein the control unit (700) is configured to compare the received value with a defined reference value and to control the humidification unit (400) based on the comparison between the received value and the defined reference value.
6. The system (100) according to any one of the preceding claims, wherein the humidifying unit (400) is arranged to wet only one side of the sheet (600), preferably the underside (601) of the sheet (600), when the sheet (600) is conveyed horizontally through the humidifying unit (400).
7. The system (100) according to any one of the preceding claims, wherein the humidifying unit (400) comprises at least one of:
an immersion unit for immersing the at least one side of the sheet (600) into the wetting agent (401),
a spraying unit for spraying the wetting agent (401) onto the at least one side of the sheet (600),
a steam unit, preferably a cold steam unit, for applying the wetting agent (401) to the at least one side of the sheet (600),
-a roller transfer unit (410) for transferring the wetting agent (401) from a reservoir (411) onto the at least one side of the sheet (600).
8. The system (100) according to any one of the preceding claims, further comprising at least one of:
a pre-drying unit for drying the sheet (600) before it reaches the forming unit (800), preferably for drying at least a portion of the sheet (600), more preferably on the at least one side, wherein the control unit (700) is further configured to control the pre-drying unit based on these values,
-a final drying unit for drying the capsule element (910),
-a filling unit for placing a quantity of brewing material (990) in the capsule cavity (911) of the capsule element (910), wherein preferably the filling unit is arranged downstream of the final drying unit, if present, with respect to the conveying direction (TD),
-a joining unit for joining a closing element (950) to the capsule element (910) to close the capsule cavity (911), preferably surrounding the quantity of brewing material (990).
9. The system (100) of claim 8, wherein the closure element (950) is
Cover (951), or
Another sachet element (910), wherein preferably the sachet elements are joined such that their cavities together form a closed sachet cavity (911).
10. The system (100) according to claim 9, wherein the system (100) comprises:
two of said forming lines (200), each forming line being intended to form one bag element, and
-a joining unit for joining two bag elements to form the bag chamber (911).
11. The system (100) according to any of the preceding claims,
Wherein the sheet (600) has gas barrier properties,
wherein preferably, the sheet (600) has a single-layer structure made of a cellulose-based material having the gas barrier property, or
Wherein preferably the sheet (600) has a multilayer structure comprising:
-a paper layer (611) made of cellulose-based material, preferably forming said at least one side of the sheet (600) and/or forming the underside (601) of the sheet (600), and
-a barrier layer (612) having a gas barrier property.
12. A method for preparing a compostable sachet (900) for a brewed product, the method comprising:
-conveying a sheet (600) made of biodegradable cellulose-based material, preferably having gas barrier properties, through the system (100) along a conveying direction (TD);
-wetting at least one side of the sheet (600) with a wetting agent (401);
-shaping a portion of the wetted sheet material (600) into a three-dimensional shape to form a sachet element (910) defining a sachet cavity (911);
-preferably drying the sachet element (910);
characterized in that the method further comprises:
visually sensing a humidity level of at least one section of the wetted sheet (600);
Receiving a value related to the sensed humidity level; and
-controlling the wetting of the at least one side of the sheet (600) based on these values.
13. The method of claim 12, wherein the step of visually sensing comprises:
capturing a visual image of at least the section of the wetted sheet (600) representative of the humidity level, and
preferably, one or more defined wavelengths of light (531) within the visible spectrum are emitted onto at least the section of the wetted sheet (600), wherein reflected light (532) is captured as the visual image.
14. The method of claim 12 or claim 13, wherein the step of controlling the wetting comprises:
compare the received value with the defined reference value, and
controlling the wetting based on the comparison between the received value and the defined reference value.
15. The method of any one of claims 12 to 14, further comprising at least one of:
-placing a quantity of brewing material (990) in the cavity (911) of the capsule element (910);
-joining a closing element (950) to the capsule element (910) to close the cavity (911), wherein the step of joining preferably comprises:
O joining a cover (951) as the closing element (950), or
-joining another capsule element (910) as the closing element, wherein preferably the capsule elements (910) are joined such that their cavities together form a closed capsule cavity (911).
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP21188641.1 | 2021-07-30 | ||
| EP22187746 | 2022-07-29 | ||
| EP22187746.7 | 2022-07-29 | ||
| PCT/EP2022/071485 WO2023007021A1 (en) | 2021-07-30 | 2022-07-30 | System and method for forming a compostable pod for beverages from a sheet having a controlled moisture level |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117693473A true CN117693473A (en) | 2024-03-12 |
Family
ID=90128735
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202280051801.3A Pending CN117693473A (en) | 2021-07-30 | 2022-07-30 | Systems and methods for forming compostable pouches for beverages from sheets with controlled moisture content |
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| Country | Link |
|---|---|
| CN (1) | CN117693473A (en) |
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