TITLE
MANUFACTURING PROCESS AND MANUFACTURING LINE FOR MANUFACTURING AN ENGRAVED
CELLULOSE-BASED CONTAINER
Field of the Invention
The present invention relates to the technical field of manufacture and production of single-use food and/or beverage containers and particularly of capsules and pods for the preparation of beverages. In particular, the present invention relates to a manufacturing process and to a manufacturing line for a capsule or a pod for the preparation of a beverage drink.
In greater detail, the present invention relates to a manufacturing process and to a manufacturing line for producing a single-use container (capsule or pod for example) usable in an automatic beverage preparation machine and containing a product in powder form, leaf form or the like (for example powdered roast and ground coffee or tea, leaf tea, soluble coffee, concentrates or freeze-dried drinks) which is destined to be mixed with a liquid (for example hot water or cold water at pressure) by interaction with the beverage preparation machine to obtain a drink.
The invention also relates to a single-use container which may be in the form of a capsule or a pod.
Background
Single-use containers for preparing a beverage in a beverage production machine are known in the art for several decades.
Containers or capsules made of cellulose-based material like paper or pulp are also known in the field of beverage preparation devices and machines. Capsules which can maintain the qualities of the beverage substance in the capsule, at least for a certain period of time have been developed. These capsules conventionally integrate a liner and/or a coating, having barrier functions, in particular over gas (oxygen) and/or water vapor or moisture.
For a capsule to be extracted in a specific system, for example, the Nespresso® Original Line system, the consumer should be able to recognize and distinguish the capsules of the different capsule's ranges to select its favorite coffee depending on the time of the day. Hence a differentiation of these capsules is needed as it is today existing for Aluminium capsules. However, the required differentiation which could, for example, be done using printing or laser engraving on the capsule should not damage the capsule and its barrier function or should be fully compatible with the food safety regulations in case inks are used.
An object of the invention is to address the above existing problems.
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; pressurisation; 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 used herein, the term "container" or "capsule" or "pod"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 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 5 - 100 ml. The capsule includes a coffee capsule, e.g. a Nespresso® capsule (including a Classic, Professional, Vertuo, Dolce Gusto 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/flavoured water, and other extractable 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 used herein, the term "precursor material" 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 flavouring, 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 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 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 fibres. 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 fibres, which may be present in one or more of the material constituents. As used herein the term "cellulosic" or "cellulosic material" may refer to conventionally woody and/or non-woody materials, e. g. manila hemp, sisal, jute, bleached and unbleached soft wood and hard wood species. A cellulosic material may include a regenerated or reconstituted cellulose. As used herein the term "natural cellulosic material" may refer to conventionally 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 fibres from one or more of wood, fibre crops, paper or rags. As used herein the term "wet formed" may refer to a process of forming from an aqueous solution of fibres. The aqueous solution of fibres may be heated and pressed in a mould to set the material and remove water therefrom.
In these respects, the invention provides a manufacturing process for producing a biodegradable, preferably compostable, single-use food and/or beverage containers for use in a beverage production machine, on a single-use container manufacturing line according to Claim 1.
In more details, the claimed manufacturing process is used for producing a biodegradable, preferably compostable, single-use food and/or beverage containers for use in a beverage production machine, on a single-use container manufacturing line, and comprises: a) supplying a cellulose-based container body having an external surface and an outwardly extending peripheral rim, b) filing the container body with a food and/or beverage ingredient, c) applying a closing element over the container body, d) sealing the closing element with the peripheral rim of the container body.
According the to invention, the manufacturing process further comprises a step of marking the container body on its external surface by printing and/or by laser engraving, said marking step taking place before the step of filling the container body with the food and/or beverage ingredient.
The proposed process allows the manufacture of a beverage container comprising differentiating information on its surface while ensuring the marking step has not damaged any portion of the container body. According to a possible feature, during the marking step (al), the container body is marked by printing and/or laser engraving in one or more locations of the container body. The marking step allows marking one or more elements that may form a pattern.
Preferably, the marking step is a laser engraving step. As laser engraving is inkless, it participates to having a fully biodegradable / compostable container solution with improved visual differentiation.
Specifically, the closing element of the container is a closing membrane or a second container body respectively forming when sealed with the peripheral rim of the container body, a capsule, or a pod.
The container, for example a coffee capsule or pod, may then be marked on its external surface at one or more specific location with marked elements or patterns.
The marked elements or patterns may form a differentiating sign that may allow the end consumer to distinguish and select the type of container he wishes. The marked elements or patterns mays be selected within the group of a logo, a brand range, a product name, a trademark, a coded information, and combination thereof, or a weakened zone.
In more details, when the container is a capsule, the container body comprises a bottom wall, a tubular lateral side wall, an annular flange connected on one side to the lateral wall and on the other side to the peripheral rim. Further to the marking step, the container body may be marked on its lateral side wall and/or on its bottom wall.
Hence depending on the type and / or size of the elements or information that is marked on the capsule, it is possible to have the marked elements only on the lateral side wall or on the bottom wall. Alternatively, the marked elements may be marked on both the lateral side wall and the bottom wall.
Specifically, when the container is a pod, the container body and the second container body, forming the closing element, comprise both a bottom wall with an outwardly peripheral rim. In this configuration, one or both container bodies are marked on its bottom wall.
This may allow the end consumer to perfectly identify the information presented on the pod and make its pod selection accordingly.
According to a further feature of the container (capsule or pod), the container body is provided with a liner and/or a coating, having at least one barrier function. The barrier function is preferably a gas barrier, preferably oxygen, and/or moisture or water vapor barrier.
Hence, it is proposed that the manufacturing process further comprises an inspecting step (a2) for inspecting the integrity of the liner and/or coating of the container body. Preferably, the inspecting step (a2) is occurring after the marking step (al) and before the filling step (b).
As a particular option, upon detection, during the inspecting step, of a damaged liner and/or coating on a container body, said container body is removed from the manufacturing line. This feature is of particular interest as it allows to remove from the line containers having a damaged barrier that would lead to unsatisfactory containers for the end user, especially when the container contains products like coffee, preferably roast and ground coffee which is sensible to gas (oxygen in particular) and/or water vapor and moisture.
As mentioned, the container body of the container is made of cellulose-based material. Cellulose-based material is a plant-based fiber material comprising woold and/or non-wood fiber material that is optionally bleached.
In more detail, the cellulose-based material is selected within the list of paper, calendared paper, parchment paper, cardboard, molded-pulp, or combination thereof.
By way of example the container body may be made of pulp-based material, preferably molded pulp-based material, preferably from paper pulp or wood pulp. In this proposed option, the container may be made using wet or dry pulp molding process.
Alternatively, the container body may be made of paper-based material, preferably formable paper-based material, preferably selected in the list of kraft paper calendared paper, parchment paper, cardboard, or combination thereof.
According to another aspect, the invention is also related to a manufacturing line for a single-use food and/or beverage container as previously described comprising a cellulose- based container body having an external surface and an outwardly extending peripheral rim. As proposed, the manufacturing line comprises:
A receiving station for receiving the container body,
A marking station for printing and/or laser engraving the container body on its external surface,
A filing station for filing the container body with a food and/or beverage ingredient,
A sealing station for sealing a closing element over the container body,
As claimed, the marking station is positioned before the filling station.
The positioning of the marking stating before the filling station makes it possible to add a specific module in the manufacturing line before the filling and sealing station which may be provided as a combo station. This may allow not redeveloping a complete manufacturing line. In particular, the marking station is a laser engraving station. The marking station may use a CO2 laser working between 9 pm and 11pm at an optical power comprised between 0.1 W and 90 W. The frequency of the laser may generally be between 1 kHz and 250 kHz and typical marking speeds may be between 800 mm/s and 20000 mm/s. Different focal points may also be used to reach the required engraving effect such as +/- 5 mm to the initial focus.
By adjusting the laser parameters and ranges, such as the pulse duration, energy density or intensity, marking speed and beam width, it is possible to reach a precise control over the depth and width of the laser marking and writing. Hence, in addition to the information to be laser engraved on the product, different type of writing (bold, caps, italic ...) ensuring an important diversity in the differentiation of the proposed containers (capsules and pods) may be obtained.
In particular, the marking station is constructed such that it may proceed to marking the container body on one or more locations on the external surface of the container body.
For example, if the container is a capsule, the marked elements or patterns may be positioned on one or more locations of the bottom wall and/or side wall.
For example, if the container is a pod, the marked elements or patterns may be positioned on the bottom walls of the first and /or second container bodies (forming the pod upper and lower walls).
The invention also proposes a single-use food and/or beverage container manufactured according to the proposed process. Such container generally comprises a cellulose-based container body, preferably a pulp-based container body or a paper-based container body comprising a peripheral rim in which the container body is provided with a liner and/or a coating, having at least one barrier function and a closing element of the container body. In addition, and according to the invention, the single-use container comprises at least one laser engraved marked element or pattern forming a differentiating sign.
As proposed the engraved marked element or pattern forms a differentiating sign selected within the group of a logo, a brand range, a product name, a trademark, a coded information, and combination thereof, or a weakened zone. This allows multiple options for differentiating the container allowing for an improved consumer benefit.
In particular, the single-use food and/or beverage container may be a capsule or a pod. And hence, the closing element is either a closing membrane or a second container body, comprising a barrier function against gas and/or water vapor, and respectively forming when sealed with the peripheral rim of the container body said a capsule or pod. By way of example, the proposed capsule or pod is a coffee capsule or coffee pod which includes a single-use food and/or beverage container as claimed.
The invention is also related to the use of a a single-use food and/or beverage container for the preparation of a beverage and/or foodstuff in a beverage preparation machine. Preferably, the single-use container is a biodegradable and/or compostable capsule or pod, preferably for preparing coffee beverages.
With the proposed manufacturing process and related manufacturing line, it is ensured that the container complies with the required high-quality standards and that the coffee ingredient stored inside the container is maintained in protected atmosphere with high protection from oxygen and water vapor.
Additionally, the proposed marked container provides improved visual differentiation for the consumer.
The above aspects of the invention may be combined in any suitable combination. Moreover, various features herein may be combined with one or more of the above aspects to provide combinations other than those specifically illustrated and described. Further objects and advantageous features of the invention will be apparent from the claims, from the detailed description, and annexed drawings.
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 is a side view of capsule body according to the invention;
Figure 2A and 2B are a photos of a capsule manufactured according to the manufacturing process of the invention presenting different laser engravings; Figure 3A is a schematic side cut-out view of a pod manufacture according to the manufacturing process of the invention;
Figures 3B and 3C are top views of a pod manufacture according to the manufacturing process of the invention presenting different laser engravings; Figure 4 is a block diagram presenting the manufacturing process of the invention; and
Figure 5 is a schematic side view of a manufacturing line of the invention. 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.
Figures 1 to 3C propose containers made from biodegradable material and marked according to the proposed process. These containers are made of biodegradable material and are in their entirety biodegradable. However, in addition to being biodegradable, they are preferably compostable and most preferably home compostable. They are made of a combination of biodegradable material, of a combination of compostable material, of a combination of home-compostable material or of a combination of biodegradable, compostable and home-compostable material.
Generally, the term "biodegradable" may be understood as meaning that a material is capable of being decomposed by bacteria or other biological means.
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.
Generally, the term "compostable" may be understood as meaning that a material may be substantially broken down into organic matter within a few weeks or months when it is composted. At the end of a composting process, the earth may be supplied with nutrients once the material has completely broken down. International standards, such as EU 13432 or US ASTM D6400, provide a legal framework for specifying technical requirements and procedures for determining compostability of a material. For instance, according to these standards, compostable materials must be biodegradable and disintegrable, i.e. fragmentation and invisibility in the final compost, and must not have negative effects on the composting process and quality. Composting may be accomplished in home composters and/or industrial composting sites. Defined conditions relating to wind, sunlight, drainage and other factors may exist at such sites. 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.
For "home compostable" requirements, home-compostable materials may be composted in home composters, such as compost barrels or a home compost bin over a period of weeks or months (e.g. at least 90% degradation of materials in 12 months at ambient temperature). As a result of the composting process, the home-compostable materials may be converted into a nutrient-rich soil. Thus, a home-compostable container can be simply disposed in a home-compost pile after its use. Further, the term "material composition" may be understood, for example, as the constitution, combination and/or arrangement of (different) materials, which preferably form (altogether) a (uniform) structure, such as the container or a section thereof.
Figures 1, 2A and 2B propose an embodiment of a container 1 manufactured according to the invention, in the form of a capsule la. Said capsule la is used for the preparation of a beverage in a beverage preparation machine, (not shown). Specifically, the capsule aims at being inserted inside a Nespresso ® Original Line beverage preparation machine to be extracted as described for example in one or more of EP0512468A1, EP0512470A1, EP1654966A1 or EP2142054A1.
This capsule la comprises a container body 2 here in the form of a cup-shaped body 2a, being opened at a first end, forming a chamber for a beverage ingredient 10, and a closing element 7. The closing element 7 is in the form of a closing membrane 7a for closing the cup-shaped body 2a at the opening location.
The cup-shaped body 2a is made of cellulose pulp and is therefore biodegradable, preferably compostable.
The closing membrane 7a is made as a laminate with barrier function and is sealed onto the cup-shaped body 2a to form a hermetic single-use container.
The term "cellulose pulp" refers to a pulp comprising cellulose fibers in a percentage higher than 50% by weight, preferably ranging from 80% to 100% by weight.
The term "cellulose fibers" refers to fibers having a wood and/or a wood free origin. The fibers, by way of non-limiting examples, are: hard wood cellulose fibers, soft wood cellulose fibers, wheat fibers, corn fibers, bagasse fibers, bamboo fibers, hemp fibers, cotton fibers, other similar vegetable or plant fibers, or a combination thereof. The cup shaped body of the capsule is preferably obtained by molding in a mold a dry or wet, preferably wet, cellulose pulp. Such capsule is presented in WO 2023/052349 Al, WO 2023/052350 Al, WO 2023/052352 Al, and WO 2023/051967 Al; the content of which are incorporated by reference. These applications disclose a pulp-molded compostable capsule and in particular its structure and forming process. This capsule, containing preferably roast and ground coffee, developed and marketed by Nespresso® is a complementary solution to aluminium capsules and is intended to be used in a Nespresso® Original Line beverage machine in the same way as the Nespresso® aluminium capsules.
Alternatively, the cup-shaped body 2a may be shaped from a sheet made of cellulose pulp, by deforming it into a mold to confer to the sheet the desired cup shape, as usual for the skilled person.
The cup-shaped body 2a comprises at least a bottom wall 3 (closing the cup-shaped body at its second end), a tubular lateral wall 4, an annular flange 5 connected to the lateral wall 4 and an outwardly extending peripheral rim 6, extending from the annular flange 5, for the closing membrane 2 to seal thereon.
As can be seen in the Figures, the cup-shaped body 2a is preferably revolutionary symmetrical (axis Al). Preferably, the tubular wall 4 has a frustoconical shape, with a circular cross section and with an increasing diameter towards the annular flange 5.
The cup-shaped body 2a also comprises stiffening portions 11, which are disposed between the lateral side wall 4 and the bottom wall 3 to stiffen the cup-shaped body 2a of the capsule la. In particular, the stiffening portions 11 aim at stiffening the bottom wall 3 that constitutes a perforation region to be perforated by one or more penetrator element of the beverage preparation machine.
The lateral wall 4 and the annular flange 5 are integral and are therefore made of the same material.
The cup-shaped body 2a further comprises a liner 8 laminated on its internal surface. The liner 8 has a barrier function, especially it is barrier to oxygen and to water vapor and moisture to allow for optimal preservation of the ingredient, preferably coffee, to be stored in the capsule la.
The liner 8 is generally made as a biodegradable multilayer structure comprising barrier function(s) to both gas and water (vapor / moisture).
Therein, the expression "multilayer structure" may be understood, for example, as a structure comprising different parts that are arranged in pleats, slats, tiers or as strata. Preferably, the layers may be arranged such that they may extend parallel to each other to form a film. Preferably the different layers are laminated so as to form a foil or a film. However, other technologies "linking" the different layers are available as for example blown and/or cast film coextrusion, extrusion coating or even sealing.
The liner 8 may be structured as multilayer compostable plastic film structure comprises one or more of: a Polylactic acid (PLA) layer, a Polybutylene succinate (PBS) layer, a Polybutylene adipate terephthalate (PBAT) layer, a Polyhydroxy alkanoate (PHA) layer, a Polycaprolactone (PCL) layer, any combination thereof.
In addition, the secondary layer comprises an oxygen barrier layer comprising one or more of: a Butenediol-vinyl-alcohol-copolymer (BVOH) layer, a Polyvinyl-alcohol (PVOH) layer, a PVOH copolymer layer, a Polyglycolic acid (PGA) layer, or a metallization coating , a SiOx based coating , an AIOx based coating or a combination thereof.
Specific combinations of material forming oxygen barrier layer that are commercially available, for example under the name Ecovio® may be used.
Additional layers comprising additional physical properties may be provided. For example, layers have moisture or water barrier function may be provided. Such layer may for example comprise cellophane, a metallization coating, a SiOx coating, or an AIOx based coating.
More particularly, at least one layer of the preferably multilayer compostable plastic film structure is enriched with Calcium Carbonate (CaCO3) in a range between 1 and 70 weight%. The use of CaCO3 is of particular interest as may reduce the quantity of expenses material, for example Ecovio® that is needed. Additionally, it does not change the barriers properties and the home-compostability.
As a consequence, the secondary layer comprises a structure preferably a multilayer structure, wherein each of the layers can be tailored to provide an individual function to the secondary layer. For example, the described multilayer structure of the secondary layer of the pod of the invention facilitates that multiple (different) materials can be used, each capable of performing at least one function. The barrier liner may alternatively be replaced by a coating providing the same functions.
As visible in Figure 2A and 2B, the lateral wall 4 of the capsule la is engraved on its external lateral side wall 4. The laser engraved element is a differentiating sign 15a, 15b which in the present case is the product range meaning the marketed name of the coffee stored in the capsule.
In Figure 2A, the capsule la has an engraved differentiating sign 15a corresponding to the capsule range "Peru" which allows the consumer to identify the capsule and related coffee contained in the capsule.
Conventionally, as the laser engraving is focused and precise, it is possible to engrave any type of information with a high definition. The resulting effect is a readable written information (here the "Peru" coffee range). In Figure 2A, the engraved differentiation sign is of similar color or appears a bit darker (due the engraving depth) as the rest of the pulp- molded container body 2 and may be qualified as a ton-on-ton written information.
In Figure 2B, the laser engraved differentiating sign 15b is visually different from the laser engraved differentiating sign 15a of the capsule la of Figure 2A. The readable written information forming the differentiating sign 15b corresponds to the capsule range "Emilia".
As it appears on Figure 2B, the differentiating sign 15b is of white color, at least of a whiter color than the cellulose-based molded pulp of the capsule body 2a. In the present case, the contrast between the material of the capsule body 2a and the differentiating sign 15b is improved.
Generally speaking, the differentiating sign may be formed by one or more engraved elements or patterns.
Additionally, the engraved differentiating sign may be any type of differentiation element or pattern. For example, it may be selected within the group of a logo, a brand range, a product name, a trademark, a coded information, and combination thereof, or a weakened zone depending on the type of differentiating sign needed to ensure sufficient differentiation for the consumer when he is selecting its coffee capsule.
The marking process of the above-described capsules is presented below in connection with Figures 4 and 5.
Figures 3A to 3C propose an embodiment of a container 1 manufactured and marked according to the invention, in the form of a pod. Said pod lb is used for the preparation of a beverage in a beverage preparation machine, (not shown). Specifically, the capsule aims at being inserted inside a Nespresso ® Professional beverage machine, using the principle described for example in WO 94/02059 and in EP 1090574 Al. The beverage production machine may comprise elements for injecting fluid into the pod lb and elements for opening the pod lb under the effect of rising pressure of a fluid that is injected into the pod lb.
Similarly to the capsule la disclosed in Figures 1 to 2B, the pod lb of Figures 3A to 3C is made of a biodegradable and more preferably made of a compostable material composition.
This pod lb comprises a container body 2 here in the form of a half-shell 2b, being opened at a first end, and a closing element 7. The closing element 7 is in the form of a (second/closing) half-shell 7b for closing the half-shell body 2b at the opening location. The half-shell 2b is preferably of revolutionary symmetry (axis A2) and comprises a circular cavity forming a chamber 9 (or storage portion) for a beverage ingredient 10, and an outwardly extending peripheral rim 6 connected to the circular chamber 9.
The half-shell body 2b is made of biodegradable, preferably compostable material and may be shaped from a sheet comprising at least a layer of cellulose-based formable material, for example paper, by deforming it into a mold to confer to the sheet the desired cup shape with a chamber 9, as usual for the skilled person.
Therein, the term "formable" may be understood, for example, as the characteristic of a material being malleable, pliable, and/or shapable, preferably with/without the support of additional tools and/or preferably with/without the application of heat and/or water, and/or compressed air.
The closing half-shell 7b is of similar material and shape as the half-shell body 2 and is sealed onto the half-shell body 2 to form a symmetric hermetic single-use container. In more detail the peripheral rim 6 of the closing half-shell 7b is attached, for example by sealing, preferable heat or ultrasonic sealing, with the peripheral rim of the half-shell body 2.
For example, as proposed in the present embodiment, both half-shells (body 2 and closing 7b) are made in the form of a multilayer structure comprising a primary layer 12, a secondary layer 13 and an optional filter layer 14 having filtering function.
Specifically, the primary Iayerl2 is arranged opposite to the chamber 9 with respect to the secondary layer 13 and therefore constitutes the external (or outer) surface of the pod lb.
In a complementary way, the tertiary layer 14 is arranged facing the chamber 9 with respect to the secondary layer 13 and therefore constitutes the interior of the chamber 9.
The primary layer 12 comprises a cellulose-based material, preferably a paper-based material. The paper-based material may be stretchable or formable paper material and/or parchment paper having an elongation at break of at least 6%. For example, the material of the half-shells 2b, 7b may be formable by being stretchable (and/or deformable permanently) in transverse and longitudinal directions. For example, the material of the halfshells 2b, 7b may comprise a formable paper material, preferably having a grammage between 50 g/m2 to 150 g/m2. For example, the formable paper material may be a Kraft paper.
The secondary layer 13 comprises a coating or a preferably multilayer compostable plastic film structure providing the required barrier functions to the pod lb. For example, it may have a similar structure as the one of the liner 8 disclosed in connection with the capsule la of Figures 1 to 2B.
The filter 14, similarly to the other layers of the half-shell body 2b, is biodegradable, preferably compostable and comprises one or more of a filter material comprising one or more of the following materials:
Polylactic acid (PLA),
Polybutylene succinate (PBS), Bio Polybutylene succinate (Bio PBS), Ecovio®, Cellulose fibers-based material, Regenerated cellulose (cellophane), or a combination thereof.
Preferably, the filter layer 14 comprises a cellulose fibers-based material that may contain one or more of a paper, a supercalendered paper and/or a filter paper.
Thanks to its filtering function, the filter layer 14 may filter out particles that otherwise may leave the chamber 9 during the beverage preparation process.
Further, the half-shells 2b, 7b may have any shape, geometry, or dimension.
Preferably, the shape of the half-shells 2b; 7b may correspond with the geometry of the pod holder of the beverage preparation machine (not represented). Such a pod structure is presented in PCT/EP2023/058915, the content of which is incorporated by reference.
In the proposed embodiment the closing element 7 is a closing half-shell 7b, however it may also be formed of a closing membrane similar to the one disclosed in connection with Figures 1 and 2 leading to a non-symmetric pod.
In the proposed embodiments the pod 1 is circular and has a total diameter including the peripheral rim of approximately 53 mm. However, the dimensions of the pod may vary, and the diameter may be comprised between 40 and 65 mm depending on the beverage preparation machine it is intended to be used in.
As can be seen in Figure 3B, the pod lb is marked on one its top side with differentiating signs 16a, here the product range (Ristretto), and a Nespresso® logo and a circle pattern having a technical function of weakening the paper-based material for extraction purpose. The differentiating signs 16a are made by laser engraving using similar engraving process and parameters as laser engraving of the differentiating sign 15a of Figure 2A, no repetition of these parameters will be done to avoid duplicating explanations. Hence, as previously presented, the differentiating signs 16a are appearing as ton-on-ton on the paper however, the differentiating signs 16a can be distinguished from the paper-based material.
In Figure 3C, the pod lb is also marked on its top side with differentiating signs 16b. The differentiating signs 16b are also the product range (Ristretto), and the Nespresso® logo. However, the result of the laser engraving is not a ton-on-ton marking but a white marking. The differentiating signs 16b are of whiter color than the paper-based material. The differentiating signs 16b are made using similar engraving process and parameters as laser engraving of the differentiating sign 15b of Figure 2B.
The marking process of the proposed pods lb is presented below in connection with Figures 4 and 5.
The manufacturing process of the invention is presented in Figure 4 as a block diagram and shows the different steps leading to the manufacturing of a biodegradable, preferably compostable, single-use food and/or beverage containers 1. This manufacturing process is implemented in a manufacturing line 20 schematically presented in connection with Figure 5.
As understood, the container 1 may be in the form of a capsule la or a pod lb as described above comprising a container body 2 closed with a closing element 7 thereby forming a storage portion 9 (cavity), the final container comprising a barrier liner 8 or coating for providing the barrier required to preserve the beverage ingredient 10 stored in the cavity 9. These containers are to be used in a beverage production machine, for example a Nespresso® Original Line machine or a Nespresso® Professional Line. However, the containers may be used in other beverage preparation machine as soon as they are compatible with such machines.
As visible in Figure 4, the manufacturing process comprises the following steps: a) supplying a cellulose-based container body 2 having an external surface and an outwardly extending peripheral rim 6, al) marking the container body 2 on its external surface by printing and/or by laser engraving, a2) optionally, inspecting the integrity of the liner 8 and/or coating of the container body 2, b) filing the container body 2 with a food and/or beverage ingredient 10, c) applying a closing element 7 over the container body 2, d) sealing the closing element 7 with the peripheral rim 6 of the container body 2.
In the first step a), the supply of the cellulose-based container body is made at a receiving station 22 designed to receive the empty container body 2. As previously disclosed the final container 1 may be a capsule la or a pod 2a. It may also be any type of container compatible with the intended use.
Going into the detail, the container body 2 may, for example, be made as a pulp- molded cup body 2a or as a paper-based half-shell 2b. As known in the art, the container body 2 comprises an outwardly extending peripheral rim 6 which, in addition to the sealing purpose for the closing element 7 to seal upon, may be used, for example, for handling the container body 2 during the manufacturing of the container 1.
The receiving station 20 is adapted to the design of the container body 2 to be received for the manufacture of the final container, which for example may be capsule la or a pod lb.
Before the filling step b), the manufacturing process comprises a step al) of marking the container body 2 on its external surface. This marking, depending on the marked elements and/or patterns, may be used to differentiate the final formed container from other containers. The marked elements and/or patterns may be one or more of a logo, a brand range, a product name or range, a trademark and combination thereof. This is, for example visible in connection with Figures 2A, 2B, 3B and 3C.
However, the marked elements and/or patterns may also be a coded information, coding for extraction parameters that are read by the beverage machine to provide the consumer with an optimized extraction, or a weakened zone used for providing a rupturing point used for extracting the product from the container.
The step al) of marking the container is made at a marking station 24 visible in Figure 5. When the marking step al uses the technology of laser engraving, the marking station 24 is a laser engraving station and integrates one or more lasers, for example CO2 lasers, positioned and configured so as to provide the required laser engraving.
As disclosed in connection with the Figures 1 to 3C, the marking of the container body 2 may, for example, be made on the external surface of the container body. For example, il may be made on one or more locations on the lateral wall 4 and/or on the bottom wall 3. The marking may be done by printing and/or by laser engraving. However, laser engraving may be preferred as proposing an inkless solution. To ensure the capsule body 2 is free of any defect on the body itself, but also on the liner 8 and/or coating, providing the required barrier against oxygen and water vapor, for example, further to the supplying step 1) or further to the marking step a2), the manufacturing process may further comprise an inspecting step a2) for inspecting the integrity of the liner 8 and/or coating of the container body 2. As visible in Figure 4, the inspecting step a2) is occurring after the marking step al). The inspecting step a2) is performed at an inspecting station 25.
The inspecting station 25 may integrate any means suitable to check and detect any damaged container body and in particular any damaged liner 8 and/or coating laminated or applied in the storage portion 9 of the container body 2. In particular, it may detect holes in the liner 8 or delamination locations of the liner 8 inside the container body 2.
The inspecting station 25 may, for example, comprises a vision system comparing the produced and marked body containers to a reference.
Upon detection, during the inspecting step a2), of a damaged liner and/or coating on a container body, said container body may be removed from the manufacturing line 20, preferably before being filled with the beverage ingredient 10.
The container body 2 is then further filled in step b) with the beverage ingredient 10. Step b) is performed at a filling station 26 which provides the required weight of beverage ingredient 10. Speaking about capsules and pods, the beverage ingredient is preferably coffee, for example, roast and ground coffee.
In step c), a closing element 7 is applied over the container body 2 so that the peripheral rim 6 of the container body is covered by the closing element 7. As mentioned, the closing element 7 may be closing membrane 7a to form a capsule la or a half-shell 7b to form a pod lb.
The sealing of the closing element 7 over the peripheral rim 6 of the container body 2 is made in step d). The sealing may be a heat sealing, an ultrasonic sealing, or any other known sealing applicable to the container manufacturing industry.
Steph c) and d) may be performed at a sealing station 28 which positions and seals the closing element 7 over the container body 2 so that the closing element 7 is attached to the rim portion 6 of the container body 2.
Filling the container body, applying the closing element and sealing the closing element corresponding to steps b), c) and d) and stations (filling 26 and sealing 28) are known in the art and are presented to get a general view on the process and manufacturing line.
The proposed manufacturing process and corresponding manufacturing line ensures that the marked container bodies supplied to the filling station 26 are not damaged avoiding the manufacturing of containers that would not provide the consumer with full satisfaction and enhanced sensory experience.
Although the invention has been described by way of example, it should be appreciated that variations and modifications may be made without departing from the scope of the invention as defined in the claims. Furthermore, where known equivalents exist to specific features, such equivalents are incorporated as if specifically referred in this specification.
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.