WO2025061644A1

WO2025061644A1 - Capsule and method of forming capsule

Info

Publication number: WO2025061644A1
Application number: PCT/EP2024/075837
Authority: WO
Inventors: Mathieu MURITH; Daniel Abegglen
Original assignee: Societe des Produits Nestle SA; Nestle SA
Current assignee: Societe des Produits Nestle SA; Nestle SA
Priority date: 2023-09-19
Filing date: 2024-09-17
Publication date: 2025-03-27
Anticipated expiration: 2026-03-19

Abstract

A capsule designed for insertion in a beverage production device for preparing a beverage from a substance contained in the capsule by introducing liquid in the capsule and passing liquid through the substance using centrifugal forces, wherein the capsule comprises a molded pulp layer defining: a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion; wherein the annular flange portion forms a curl extending transversally and axially beyond the flange-portion. A method of preparing a capsule, the method comprising: a. providing a pulp molding tool defining the shape of a capsule comprising a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion, b. shaping the pulp by aspiration, pressing and drying to form the capsule, and c. forming a curl in a flange-like rim of the capsule.

Description

CAPSULE AND METHOD OF FORMING CAPSULE

Field of the invention

The present invention relates to a capsule designed for preparation of a beverage by centrifugation, the use of a capsule in a beverage producing device and a capsule system combining a capsule and a beverage producing device for preparing a beverage from a beverage substance contained in the capsule and by passing a liquid fed by the device through the substance in the capsule using centrifugal forces.

Background of the invention

There exist systems for preparing beverages such as coffee by forcing a liquid through ingredients contained in the capsule using centrifugal forces.

WO 2008/148604 for example relates to a capsule for preparing a beverage or liquid food from a substance, in a centrifugal brewing unit, by passing water through the substance contained in the capsule by using brewing centrifugal forces comprising: an enclosure containing a predetermined dose of substance; opening means which opens under the centrifugal effect to allow the brewed liquid to leave the capsule. The capsule may also comprise means for engaging the capsule external rotational driving means of a centrifugal brewing device wherein the engaging means are configured to offer a resistance to torque during rotation of the capsule for maintaining the capsule in a reference rotational position.

WO 2011/092301 for example relates to a capsule designed for insertion in a beverage production device for preparing a beverage from a substance contained in the capsule by introducing liquid in the capsule and passing liquid through the substance using centrifugal forces, the capsule comprising: a body comprising a bottom end and an open end, spaced apart in the axial direction, an upper wall for covering the body at its open end, along a direction transverse to the axial direction, an enclosure between the body and upper wall containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, wherein the flange- like rim comprises an annular flange portion; wherein the capsule comprises an annular pressure-setting ring configured for being engaged by a valve member of the beverage production device to provide a flow restriction valve for the centrifuged beverage flow leaving the capsule; wherein the annular pressure-setting ring extends transversally and axially beyond the flange-portion. The pressure-setting ring is more particularly designed to adjust the backpressure formed by the valve means when inserted in the beverage production device. When in use, the capsules are exposed to water at 92°C with a pressure of 1.5 bar. The centrifugal extraction process generates also forces of up to 500N which are acting on the capsule body. To withstand the moisture, temperature and pressure of the beverage extraction process, capsules for centrifugal beverage production are made from aluminium, aluminium alloy or plastic packaging. The current aluminum capsules are rigid and geometrically stable during the beverage extraction process.

While aluminium and aluminium alloy capsules can be made using 80% recycled aluminium and can themselves be recycled, there is a desire for alternatives that minimize material use and are compostable.

Molded pulp is a material that is used with increasing frequency for packaging, particularly of foodstuffs. A key benefit of these materials is that they are easily recycled and biodegrade, often being home compostable. Existing technologies of molded pulp allow the production of rigid containers such as paper cans, paper bottles or capsules for beverage. Being made of cellulosic fibers, it is usually necessary to coat or laminate the molded pulp in order to add sealing and barrier properties (e.g. to prevent ingress of oxygen).

While replacements for aluminium and plastics is desirable, replacing aluminium or plastics with paper in food and beverage packaging is not an easy task. A change in packaging material must not compromise consumer safety. The packaging must serve to protect the food or beverage product, but must also be robust enough to be handled by machines during the production and, in the case of beverage extracting processes, during that process. The packaging must allow that the food product is presented and protected effectively.

The provision of molded pulp packaging with effective barriers to moisture, oxygen and the requisite mechanical properties remains a challenge and significant additional processing is required to provide a suitable barrier and strength.

Summary of the invention

The objective of the present invention is to improve the state of the art and, in particular, to provide recyclable and compostable capsules for beverage extraction, in particular coffee capsules.

In order to solve the problem of reducing aluminium use, the inventors initially provided a molded pulp capsule having substantially the same shape as a capsule described in WO 2008/148604. However, working within the narrow design constraints in order to be fully retrospectively compatible with existing machines, the molded pulp capsule was very thin in the rim area. As a result, water from the beverage extraction process affected the rim and the molded capsule body tore under the moisture, temperature and pressure of the beverage extraction process. The result is shown in Fig. 1.

Consequently, the objectives of the present invention are achieved by the subject matter of the independent claims. The dependent claims further develop the concept of the present invention.

The present inventors propose to solve the above problems by providing a capsule designed for insertion in a beverage production device for preparing a beverage from a substance contained in the capsule by introducing liquid in the capsule and passing liquid through the substance using centrifugal forces, wherein the capsule comprises a molded pulp layer defining: a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion; wherein the annular flange portion forms a curl extending transversally and axially beyond the flangeportion.

The present invention further provides a method of preparing a capsule, the method comprising:

- providing a pulp moulding tool defining the shape of a capsule comprising a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion; wherein the capsule comprises an annular pressure-setting ring configured for being engaged by a valve member of the beverage production device to provide a flow restriction valve for the centrifuged beverage flow leaving the capsule,

- shaping the pulp by aspiration, pressing and drying to form the capsule, and

- forming a curl in a flange-like rim of the capsule.

Brief description of the drawings

Fig. 1 is a perspective view of a capsule according to Comparative Example 1 after attempted beverage extraction.

Fig. 2 represents a process for preparing a capsule according to the invention.

Fig. 3 represents a side view of a beverage capsule according to the invention. Fig. 4 represents part of a process for preparing a capsule according to the invention.

Fig. 5 represents part of a process for preparing a capsule according to the invention.

Detailed description of the invention

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".

By "dispersion coating", it is meant a coating technique whereby an aqueous dispersion of fine polymer particles or polymer solution is applied to the surface of paper or board as such, in order to form a solid, non-porous film after drying. Dispersion coating can be performed by gravure, flexo-gravure, rod, blade, slot-die, curtain air knife, roll coating or any other known method of paper coating. Dispersion coating can create a much thinner layerthan extrusion lamination and/or adhesive lamination, since the polymer is mixed in an aqueous water solution. This brings advantages in terms of quantity of polymer usage, its barrier performance and recyclability of resulting paper structure. The target of dispersion coating is to achieve a barrier layer against water, water vapour, grease, oil, gas, etc. by environmentally friendly coating. Another target is to prepare surface of paper material for a vacuum deposition process.

In the present specification, a "thermoforming process" allows to form three-dimensional objects (such as bottles, trays, cups, bowls, coffee capsules or pods and the like), and requires the use of heat to form in a shaped mould, an initially flat material into a three-dimensional shape. This process requires the application of pressure in addition to heat, for several seconds, such that the object, once formed into a three- dimensional item, retains its final shape.

By "fiber", it is meant a cellulosic fiber, which is generally extracted from plants, seeds or trees; such fibers contain not only cellulose molecules, but also hemi-cellulose as well as lignin.

By "moulded pulp articles", also known as "moulded fiber articles", it is meant articles that are formed by the moulding of fibrous materials. The fibrous materials may be obtained by recycling processed fiber sources, such as paper or cardboard, or obtained directly from natural fiber sources, such as sugarcane bagasse, bamboo, and straw. Moulded pulp articles are commonly used for packaging and is widely considered to be sustainable. By "continuous barrier" it is meant that the material that forms the continuous barrier is substantially free of through holes. The continuous barrier is not limited to a flat plane or layer following the surface of the underlying moulded pulp, but may have a complex topography due to the stochastic distribution of the particles from which the continuous barrier is formed.

A first aspect of the present invention relates to a capsule designed for insertion in a beverage production device for preparing a beverage from a substance contained in the capsule by introducing liquid in the capsule and passing liquid through the substance using centrifugal forces. The capsule comprises a molded pulp layer defining: a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion; wherein the annular flange portion forms a curl extending transversally and axially beyond the flangeportion.

When the annular flange portion forms a curl extending transversally and axially beyond the flangeportion, a sufficient strength is a provided to the flange-like rim and a sufficient seal is formed between the flange-like rim and the machine that water does not affect the flange-like rim and the molded capsule body does not tear under the moisture, temperature and pressure of the beverage extraction process.

By "curl" or "curled end", it is meant a portion of substantially rolled material, e.g., a rolled ply, forming a portion in relief at the free end of the flange-like rim of the capsule. The curl of material can be partially or fully rolled over. Rolling of the curl can be obtained by different techniques such as forming, embossing, deep-drawing, etc. More preferably, the curl is rolled over to form a substantially closed, hollow curl. Such characteristic provides the advantage to maintain a relatively light structure while providing a sufficient resistance to the deformation of the ring in axial direction when it is pressed by the valve member. Furthermore, it enables to use package materials in the form of a sheet such as by deep-drawing, pressing or forming. In embodiments, the capsule comprises a fiber layer, preferably a natural fiber layer, for example seed hairs such as cotton, stem or bast fibers such as flax or hemp, leaf fibers such as sisal, or husk fibers such as coconut, or a combinations thereof.

In embodiments, the capsule comprises a woven fiber layer, preferably a woven fiber matrix layer. For example, the capsule may comprise a woven fiber layer, preferably a woven fiber matrix layer, of a natural fiber layer, for example seed hairs such as cotton, stem or bast fibers such as flax or hemp, leaf fibers such as sisal, or husk fibers such as coconut, or a combinations thereof. In preferred embodiments, a woven flax fiber is used.

In embodiments, the woven fiber layer is embedded within the molded pulp layer. The woven fiber layer is designed to reinforce the capsule body and absorb the expansion load generated by the extraction process.

When present, the woven fiber layer reinforces the capsule providing high resistance to the thin wall structure of the capsule.

In embodiments, the fiber layer comprises fibers having a fiber diameter of from about 1 to about 100 pm. In preferred embodiments, the the fiber layer comprises fibers having a fiber diameter of from about 5 to about 50, from about 10 to about 20, or from about 12 to about 16 pm.

In embodiments, the fiber layer comprises fibers having a tensile strength of from about 900 mPa to about 2500 mPa, preferable from about 1200 mPa to about 2000 mPa, or from about 1500 mPa to about 1800 mPa.

In embodiments, the curl extends axially beyond the flange-portion in a direction away from the bottom end by from about 1.0 mm to about 1.6 mm, preferably by about 1.55 mm.

In embodiments, the curl extends axially beyond the flange-portion in a direction towards from the bottom end by from about 0.3 mm to about 0.6 mm, preferably by about 0.45 mm.

In embodiments, the flange-like rim comprises a water-resistant polymer. The water-resistant polymer may be any one selected from the group consisting of starch, thermoplastic starch, hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyolefin, polyester, polylactic acid (PLA), polyvinyl alcohol (PVOH), polyhydroxyalkanoates (PHA), polyvinylidene chloride (PVDC), polybutylene-succinate, polyglycolic acid (PGA), butenediol vinyl alcohol (BVOH), poly(butylene succinate-co- butylene adipate) PBSA, polybutylene adipate terephthalate (PBAT), and combinations thereof. The water- resistant polymer may in particular be a compostable polymer or biopolymer such as starch, hydroxypropyl cellulose, or hydroxypropyl methylcellulose.

The water-resistant polymer may be provided as a continuous barrier on the surface of the molded pulp layer.

In some embodiments, the water-resistant polymer is one that has been applied by a polymer dispersion coating process, a polymer extrusion coating process, or a polymer lamination coating process. In particularly preferred embodiments, the outer side polymeric layer is one that has been applied by a polymer dispersion coating process. In some embodiments, the water-resistant polymer is provided as a layer having a thickness of from 1 to 150 pm. In embodiments, the water-resistant polymer is provided as a layer having a thickness of from 15 to 130 pm, preferably from 20 to 100 pm, more preferably from 30 to 80 pm, or most preferably from 40 to 60 pm. In alternative embodiments, the coating has a thickness of from 5 to 35 pm, more preferably a thickness of from 8 to 20 pm, most preferably a thickness of from 10 to 15 pm.

In embodiments, the polymer is water dispersible. Being water dispersible enables the use of aqueous dispersions in the production of the moulded articles, which are more environmentally friendly and cost effective. In embodiments, the polymer is biodegradable. Being biodegradable enables the moulded pulp article to be biodegradable. Preferable, the polymer is selected from polylactic acid (PLA), polyvinyl alcohol (PVOH), polyhydroxyalkanoates (PHA), polyglycolic acid (PGA), butenediol vinyl alcohol (BVOH), poly(butylene succinate-co-butylene adipate) PBSA, polybutylene adipate terephthalate (PBAT), and combinations thereof.

In some embodiments, the capsule is at least partially filled with an edible product for human or animal consumption.

Preferably, said edible product is a powder, granules or grounds and is selected from the group consisting of: ground coffee, soluble coffee, tea, soluble tea, chocolate-based products such as cocoa powder, dairy products such as milk powder or powdered creamer, and combinations thereof. Also provided is a packaged edible product, comprising the capsule as defined herein at least partially filled with an edible product for human or animal consumption as defined herein.

In a second aspect, there is provided a method of preparing a capsule, the method comprising: a. providing a pulp molding tool defining the shape of a capsule comprising a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion, b. shaping the pulp by aspiration, pressing and drying to form the capsule, and c. forming a curl in a flange-like rim of the capsule.

In embodiments, the method comprises: d. providing a water-resistant polymer on the flange-like rim.

Step d may occur by applying the water-resistant polymer to the shaped article after step b and before step c or after step c. The water-resistant polymer may be added by dispersion coating, e.g., applying an aqueous dispersion of the water-resistant polymer to the surface of the molded pulp, or by laminating a layer of water-resistant polymer to the molded pulp, e.g., by a thermoforming process to attach a polymer layer onto the surface of the molded pulp. Alternatively, or additionally, step d may occur during step b by a dispersion process in which an aqueous dispersion of the water-resistant polymer is added to the wet pulp before or during shaping.

In embodiments, the method comprises: e. providing a woven fiber layer, f. mounting the woven fiber layer on the pulp molding tool, g. shaping the pulp by aspiration, pressing and drying on, through or around the fiber layer to form the capsule.

When present, steps e and f take place after step a and before step b; and step g replaces step b. Accordingly, the molded pulp is formed on, through and/or around the woven fiber layer to provide the capsule having the woven fiber layer adhered to and/or encased within the molded pulp. In embodiments, the method comprises: h. providing a water-resistant polymer on the woven fiber layer.

Step h may occur by applying the water-resistant polymer to the woven fiber layer after step e and before f, after step f and before step g, or after step g. The water-resistant polymer may be added by dispersion coating, e.g., applying an aqueous dispersion of the water-resistant polymer to the surface of the woven fiber layer. Alternatively, or additionally, step d may occur during step g by a dispersion process in which an aqueous dispersion of the water-resistant polymer is added to the wet pulp before or during shaping.

The materials and form of the capsule of the second aspect are as substantially described for the first aspect.

In a third aspect, there is provided a capsule designed for insertion in a beverage production device for preparing a beverage from a substance contained in the capsule by introducing liquid in the capsule and passing liquid through the substance using centrifugal forces, wherein the capsule comprises a molded pulp layer defining: a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, wherein the capsule comprises a fiber layer, preferably a natural fiber layer, for example seed hairs such as cotton, stem or bast fibers such as flax or hemp, leaf fibers such as sisal, or husk fibers such as coconut, or a combinations thereof.

That is to say, the capsule does not necessarily comprise the annular flange member or the curl but is instead prevents from rupture by the fiber layer. The capsule may in addition comprise the annual flange member and the curl.

The materials and form of the capsule of the third aspect are otherwise as substantially described for the first aspect.

The above and other aspects and embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings. Fig. 1 shows a capsule according to Comparative Example 1 (not according to the invention) after processing in a beverage extraction machine. Comparative Example 1 is a coffee capsule made from a single molded pulp layer defining a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a substantially flat flange-like rim extending outwardly from the body. During beverage extraction, the moisture, temperature and pressure exerted on the capsule resulted in a rupture.

Fig. 2 represents a scheme for preparing a capsule according to the invention. A weft 100 is cut from a sheet of woven fiber 101. The weft 100 is soaked in water-soluble polymer biopolymer or starch-based solution. The weft 100 is shaped by a weft-forming tool 104 to give fiber preform 106. The fiber preform is mounted on a pulp-molding tool 108, which is the subject to pulp aspiration in the slurry tank 110 under vacuum to give wet pulp and fiber preform 112, which can then be subject to final pressing, drying and shaping.

Fig. 3 represents a side view of a capsule according to the invention. The capsule preferably comprise a cup-shaped body 2, a circular, annular flange-like rim 3 and an upper wall member of disc form, preferably, a perforable membrane 4. The cup-shaped body 2 may have a bowl as illustrated or other forms. Thereby the membrane 4 and the body 2 enclose an enclosure respectively ingredient compartment 6. The membrane 4 is preferably connected onto an inner annular flange portion of the rim 3 that is preferably between 1 to 5 mm. The membrane 4 is connected to the rim 3 of the body by a seal such as a heat or ultrasonic weld line. The body 2 of the capsule 1C has a convex portion 5c of variable depth d3. However, the portion 5c may as well be a truncated or a cylindrical portion or a combinations of portions of different shapes such as truncated, cylindrical, spherical, etc. The capsule of the invention, as illustrated in Fig. 3 more particularly comprises at its flange-like rim 3, an annular flange portion 8 protruding both upwardly and downwardly from the inward flange portion 7. The pressure-setting ring 8 of the capsule is formed by a rolled over edge or curl of the flange-like rim thereby forming a curl which may be closed or partially closed. In particular, the curl can be formed from a ply of material by any suitable forming technique such as embossing, stamping, moulding, etc. The body 2 of the capsule is preferably rigid or semi-rigid. The capsule is formed from a molded pulp layer, optionally in combination with a woven fiber layer and/or water-resistant polymer layer/coating.

Figs. 4 and 5 show the formation of the curl according to the invention. Fig. 4A represents the capsule body 200, flange-like rim 202 and the annular flange portion 204 formed from the molded pulp layer. Fig. 4B shows a layer of water-resistant polymer liner 206 laminated to the molded pulp layer by thermoforming. Fig. 4C represents curl 208 formed in the flange-like rim 202.

Fig. 5A shows the initial position of the capsule rim 302 between a seam roll 300 and a chuck 303 if the rim curling process. After a first operation, the capsule rim has the shape shown in Fig. 5B. After a second operation, the capsule rim has the shape shown in Fig. 5C.

Claims

1. A capsule designed for insertion in a beverage production device for preparing a beverage from a substance contained in the capsule by introducing liquid in the capsule and passing liquid through the substance using centrifugal forces, wherein the capsule comprises a molded pulp layer defining: a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion; wherein the annular flange portion forms a curl extending transversally and axially beyond the flangeportion.

2. The capsule according to claim 1, wherein the capsule comprises a fiber layer, preferably a natural fiber layer, for example seed hairs such as cotton, stem or bast fibers such as flax or hemp, leaf fibers such as sisal, or husk fibers such as coconut, or a combinations thereof.

3. The capsule according to claim 1 or 2, wherein the capsule comprises a woven fiber layer, preferably a woven fiber matrix layer.

4. The capsule according to claim 2 or 3, wherein the fiber layer comprises fibers having a fiber diameter of from about 10 to about 20 pm, preferably from about 12 to about 16 pm.

5. The capsule according to any of claims 2 to 4, wherein the fiber layer comprises fibers having a tensile strength of from about 1200 mPa to about 2000 mPa, preferably from about 1500 mPa to about 1800 mPa.

6. The capsule according to any of claims 1 to 5, wherein the curl extends axially beyond the flangeportion in a direction away from the bottom end by from about 1.0 mm to about 1.6 mm, preferably by about

1.55 mm.

7. The capsule according to any of claims 1 to 6, wherein the curl extends axially beyond the flangeportion in a direction towards from the bottom end by from about 0.3 mm to about 0.6 mm, preferably about 0.45 mm.

8. The capsule according to claim 1 to 7, wherein the flange-like rim comprises a water-resistant polymer.

9. The capsule according to claim 8, wherein the water-resistant polymer layer is provided as a coating on the fiber layer.

10. The capsule accordingto claim 8 or 9, wherein the water-resistant polymer is provided as a coating on the surface of the molded pulp layer.

11. The capsule according to any of claim 8 to 10, wherein the water-resistant polymer is any one selected from starch, thermoplastic starch, hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyolefin, polyester, polylactic acid (PLA), polyvinyl alcohol (PVOH), polyhydroxyalkanoates (PHA), polyvinylidene chloride (PVDC), polybutylene-succinate, polyglycolic acid (PGA), butenediol vinyl alcohol (BVOH), poly(butylene succinate-co-butylene adipate) PBSA, polybutylene adipate terephthalate (PBAT), and combinations thereof, preferably a compostable polymer or biopolymer such as starch, hydroxypropyl cellulose, or hydroxypropyl methylcellulose.

12. A method of preparing a capsule, the method comprising: a. providing a pulp molding tool defining the shape of a capsule comprising a body comprising a bottom end and an open end, spaced apart in the axial direction, an enclosure between the body and upper wall for containing an amount of beverage substance, the capsule comprising a flange-like rim extending outwardly from the body, the flange-like rim comprising an annular flange portion, b. shaping the pulp by aspiration, pressing and drying to form the capsule, and c. forming a curl in a flange-like rim of the capsule.

13. The method of claim 12, wherein the method comprises: d. providing a water-resistant polymer on the flange-like rim.

14. The method of claim 12 or 13, wherein the method comprises: e. providing a woven fiber layer, f. mounting the woven fiber layer on the pulp molding tool, g. shaping the pulp by aspiration, pressing and drying on, through or around the fiber layer to form the capsule.

15. The method of claim 14, wherein the method comprises: h. providing a water-resistant polymer on the woven fiber layer.