BEVERAGE POWDER AND METHOD

Abstract

This invention provides for an agglomerated beverage ingredient powder comprising a median particle size (D50) of between 200 and 1000 microns and a density of between 250 and 950 g/l.

Claims

1. An agglomerated beverage ingredient powder comprising a median particle size (D50) of between 150 and 1000 microns and a density of between 250 and 950 g/l.

2. The agglomerated beverage ingredient powder of claim 1, wherein the powder comprises a median particle size (D50) of between 150 and 600 microns and a density of between 250 and 850 g/l.

3. The beverage ingredient powder of claim 2 wherein the powder comprises a median particle size (D50) of between 200 and 600 microns and a density of between 350 and 650 g/l.

4. The beverage ingredient powder of claim 1 wherein the beverage ingredient powder further comprises percentage of particles having a largest dimension of less than 90 microns of between 2%-20%.

5. The beverage ingredient powder of claim 1 wherein the beverage ingredient powder further comprises a water activity of less than 0.45.

6. The beverage ingredient powder of claim 1 wherein the beverage ingredient powder comprises fat.

7. The beverage ingredient powder of claim 6 wherein the beverage ingredient powder comprises between 5%-70% wt fat.

8. The beverage ingredient powder of claim 7 wherein the beverage ingredient powder comprises a median particle size (D50) of between 150 and 1000 microns and a density of between 700 g/l and 950 g/l and between 5%-25% wt fat.

9. The beverage ingredient powder of claim 1 wherein the beverage ingredient powder is selected from a chocolate powder; a milk powder; or a non-dairy creamer powder.

10. The beverage ingredient powder of claim 1 wherein the beverage ingredient powder further comprises a porosity of between 0.1 and 0.8.

11. A method of making the beverage ingredient powder of claim 1 comprising steps of: a) Fluidising a bed of beverage ingredient powder with the introduction of a gas; b) Spraying liquid droplets onto the fluidised bed of beverage ingredient powder; c) Drying the fluidised bed of beverage ingredient powder; d) Cooling the fluidised bed of beverage ingredient powder; and

12. The method of claim 11 wherein the gas is heated to between 50 to 70 C. during at least a portion of steps b) and/or c) and cooled to between 5 to 25 C. during at least a portion of step d).

13. The method of claim 11 wherein the gas is delivered at a flow rate of between 400 to 700 Nm.sup.3/h.

14. The method of claim 11 wherein the liquid droplets are sprayed at between 1 to 3 bar and at between 0.5 to 3 kg/h.

15. The method of claim 11 wherein the ratio of sprayed liquid droplet volume to beverage ingredient powder volume is between 1:99 to 1:9.

16. The method of claim 11 wherein the total residence time of the beverage ingredient powder within steps a)-d) is between 20 to 60 minutes.

17. A beverage preparation machine-insertable beverage ingredient container containing the agglomerated beverage ingredient powder of claim 1.

18. A beverage preparation machine-insertable beverage ingredient container of claim 17 wherein the beverage ingredient powder occupies between 45%-95% of the total volume of the beverage ingredient container.

19. A method of preparing a beverage comprising: a) providing a beverage ingredient container of claim 17; b) transporting fluid through the container; and c) dissolving and/or suspending at least some of the beverage ingredient powder in the fluid such that fluid exiting the container comprises at least a portion of the beverage ingredient powder dissolved and/or suspended therein.

20. The method of claim 19 wherein the fluid transported in step b) is transported under a pressure of less than 10 bar.

21. The method of claim 19 wherein the beverage ingredient container is inserted into a beverage preparation machine before step b).

22. The method of claim 21 wherein the beverage preparation machine reads a code on or in the beverage ingredient container prior to step b) and adjusts at least one parameter of the fluid that is transported through said beverage ingredient container based on the information read from said code.

23. The method of claim 19 wherein the volume of fluid transported through the container is 50 ml to 300 ml.

Description

[0097] In order that the invention may be more clearly understood embodiments will now be described, by way of example only, with reference to the accompanying drawings, of which:

[0098] FIG. 1 is a schematic of a continuous agglomeration system used in a method of the invention to produce agglomerated powders of the invention.

[0099] FIG. 2 is a comparison of an agglomerated chocolate powder of the invention to a control chocolate powder of the prior art.

[0100] FIG. 3 is a comparison of residues remaining in beverage ingredient containers after beverage preparation in a range of different beverage preparation machines

[0101] FIG. 4a is a comparison of the water activities of a 3.sup.rd chocolate powder of the invention and an Improved chocolate powder of the invention over shelf life

[0102] FIG. 4b is a comparison of 3.sup.rd chocolate powder of the invention and an Improved chocolate powder of the invention over shelf life

EXAMPLES

Example 1: An Apparatus Used in a Method of Manufacturing an Agglomerated Powder of the Invention

[0103] Referring to FIG. 1, a continuous agglomeration system (2) used in methods to manufacture powders of the invention is shown. The continuous agglomeration system (2) comprises an inlet (6) and an outlet (8) for a beverage ingredient powder (4). The system (2) further comprises a wetting zone (10) with spray nozzles (12); a drying zone (14) without spray nozzles and a cooling zone (15) without spray nozzles, a plurality of air inlets (16), air distributor (18) and air exhaust (20).

[0104] The beverage ingredient powder (4) is passed through the continuous agglomeration system (2) from inlet (6) to outlet (8); leaving the system (2) as agglomerated beverage ingredient powder.

[0105] The inlet (6) is configured to deliver pre-beverage ingredient powder (4) to the start of the agglomeration process. The spray nozzles (12) are configured to create the wetting zone (10) where the surface of the beverage ingredient powder (4) is wetted and particles of beverage ingredient powder can agglomerate. The air inlet (16) and air distributor (18) are configured to deliver air to the bed of beverage ingredient powder and provide agitation (to avoid excessive agglomeration) and drying (to complete the agglomeration process). The outlet (8) is configured to deliver post-agglomeration beverage ingredient powder for further processing or packing

[0106] In use, a beverage ingredient powder (4) may be a single ingredient or a pre-blended concoction of suitable different ingredients. The beverage ingredient powder (4) is passed through the inlet (6) to form a bed of beverage ingredient powder. The bed of beverage ingredient powder is fluidised by gas directed via inlets (16) through a distributor (18) underneath the bed of powder. The gas may be subject to heating or cooling before arriving at the fluidised bed of beverage ingredient powder.

[0107] Firstly, the fluidised bed of beverage ingredient powder enters a wetting zone (10) within the continuous agglomeration process. The wetting zone (10) is created by a number of spray nozzles (12) that dispense droplets of fluid in the form of water, that may comprise further ingredients such as an emulsifier or sweetening agent, onto the fluidised bed of beverage ingredient powder. The water droplets are defined by the pressure at which the fluid arrives at the spray nozzles (12), the flow rate of the fluid and the geometry of the spray nozzles (12) themselves, all of which are controllable by the operator. The beverage ingredient powder has a residence time within the wetting zone (10) that can be defined by the operator to modify the properties of the beverage ingredient powder (4) after processing.

[0108] After time in the wetting zone (10) the fluidised bed of beverage ingredient powder moves to the drying zone (14) of the continuous agglomerator, away from the addition of water droplets. In the drying zone (14) the gas used to fluidise the bed of beverage ingredient powder is typically heated to a temperature higher than that of the gas that was used in the wetting zone (10) in order to facilitate the efficient drying of the beverage ingredient powder. The residence time of the beverage ingredient powder in the drying zone (14) is also under the control of the operator and will affect the final properties of the beverage ingredient powder (4).

[0109] After time in the drying zone (14), the fluidised bed of beverage ingredient powder moves to the cooling zone (15) of the continuous agglomerator. In the cooling zone (15) the gas used to fluidise the bed of beverage ingredient powder is typically cooled (or heated less) to a lower temperature than the gas that was used in the wetting zone (10) or the drying zone (14) in order to facilitate the cooling and hardening of the beverage ingredient powder (4). The residence time of the fluidised bed of beverage ingredient powder within the cooling zone (15) is controllable by the operator and has an effect on the final properties of the beverage ingredient powder (4).

[0110] After time in the cooling zone the beverage ingredient powder (4) exits the continuous agglomerator via outlet (8) and on to further processing such as blending with other ingredients or packing

Example 2Preparation of an Embodiment of a Chocolate Beverage Powder of the Invention

[0111] An embodiment of a beverage ingredient powder of the first aspect of the invention, in the form of a chocolate powder, was prepared as set out below:

[0112] Using an embodiment of an agglomeration process of the second aspect of the invention, with reference to FIG. 1, a control chocolate powder, comprising 42% sucrose, 22% skimmed milk powder, 10% whole milk powder, 9% cocoa powder, 3% coconut oil, 6% glucose syrup solids, 5% sweet whey powder and some additional minor ingredients such as flavourings, was passed through the continuous agglomeration system (2) from inlet (6) to outlet (8) using the process parameters set out in Table 1; and leaving the system (2) as agglomerated chocolate powder of the invention.

TABLE-US-00001 TABLE 1 Agglomeration process parameters for production of chocolate powder of Example 2 Process Parameter Value Product throughput (kg h.sup.1) 25 Mean residence time in continuous agglomerator (min) 42 Spraying liquid, Spray rate (kg h.sup.1) Water 1.2 Atomization pressure of spraying liquid (bar) 1.8-2.2 Ratio Water/Beverage ingredient powder (%) 4.8 Air flow volume (Nm.sup.3 h.sup.1) 550 Inlet air temperature ( C.) Wetting zone 58-60 Inlet air temperature ( C.) Drying zone 70 Inlet air temperature ( C.) Cooling zone 15 Product temperature ( C.) Wetting zone 42.3-45.0 Product temperature ( C.) Drying zone 42.7-44.6 Product temperature ( C.) Cooling zone 38.2-40.5 Mean residence time (minutes) Wetting zone 10.5 Mean residence time (minutes) Drying zone 21 Mean residence time (minutes) Cooling zone 10.5

[0113] The agglomerated chocolate powder produced in this way had physical properties as set out in Table 2, which also indicates the equivalent properties of the control chocolate powder, before agglomeration:

TABLE-US-00002 TABLE 2 Physical properties of the chocolate powder of Example 2 Bulk Tapped Fines density density Hausner's D50 Q90 Water Powder (g/l) (g/l) Ratio (m) (%) Porosity activity Chocolate 651.4 761 1.15 169.7 27.3 0.52 0.32 (Control) Chocolate 564 636.9 1.13 192.2 14.15 0.60 0.25 (According to the invention)

[0114] Bulk Density and Tapped Density

[0115] These were measured by calculation from mass and volume. Bulk density, sometimes known as free flow density, was measured before any tapping, or vibration to settle the powder. Tapped density was measured after a tapping routine.

[0116] Steps for measurement of both densities were as follows:

[0117] Bulk Density [0118] 1Powder was placed into a plastic bag and mixed gently by hand 15 times using a circular motion to ensure it was in a free-flowing state. [0119] 2An amount of the powder sufficient to fill a 250 ml beaker, was poured in a steady, free-flowing motion into a graduated cylinder and the volume occupied by the powder read off. [0120] 3The ratio of mass and volume of the powder was used to calculate Bulk/Free flow density.

[0121] Tapped Density [0122] 1After measuring the Bulk Density as described above, the powder of Example 2 was placed in a tap volumeter, such as that manufactured by Agilent Technologies. [0123] 2The tap volumeter was set to a cycle of 150 strokes/taps, after which the volume occupied by the powder was read from the graduated cylinder. [0124] 3After the tapping cycle the ratio of mass and volume was used to calculate Tapped density.

[0125] Porosity

[0126] Porosity was measured by using the equation:

Porosity=(1Bulk density/Particle density)

[0127] The Particle density was measured using an Accupyc 1300 Helium Pycnometer (manufactured by Micromeritics Instrument Corporation, USA) by the following process: [0128] 13-4 g of powder was weighed in a cylinder [0129] 2The cylinder was inserted into the pycnometer and the particle density was measured.

[0130] Hausner's Ratio

[0131] Hausner's ratio was calculated as the tapped density of the powder divided by the bulk density of the powder.

[0132] Fines/Particle Size

[0133] These were measured by using a laser diffraction method on Helos Particle Size Distribution measurement equipment (Helos/KF manufactured by Sympatec GmbH) in the following way: [0134] 1A sample of powder was placed into a plastic bag and mixed gently by hand 15 times using a circular motion to ensure it was in a free-flowing state. Then the chocolate powder was placed in a Turbula mixer and allowed to equilibrate to ambient temperature (22 C.) [0135] 2The Vibri funnel was filled with 35-50 g of the powder and the instrument set to analyse Median particle size (D50) and the amount of particles with largest dimension below 90 microns (Q90).

[0136] The settings in Table 3 and Table 4 were used to measure the various powders:

TABLE-US-00003 TABLE 3 Setting used to analyse particle size Sample type Calculation mode Lens Trigger conditions Dispersing conditions Non-dairy creamer LD or free R5 Reference: 15 s Vibri speed: 100% (forced stability 1) Start: ch 25 1.0% Vibri funnel rotation: 90% Stop: ch 25 1.0% Vibri gap: 8 mm 2 s time out Primary pressure 1.5 bar. Chocolate powder LD or free R6 or R7 Reference: 15 s Vibri speed: 100% (forced stability 1) Start: ch 25 0.3% Vibri funnel rotation: 90% Stop: ch 25 0.3% Vibri gap: 1 mm 2 s time out Primary pressure 1.0 bar. Whole milk powder LD or free R5 Reference: 15 s Vibri speed: 100% (forced stability 1) Start: ch 25 1.0% Vibri funnel rotation: 90% Stop: ch 25 1.0% Vibri gap: 8 mm 2 s time out Primary pressure 1.5 bar.

TABLE-US-00004 TABLE 4 Lens parameters Lens code Focal length (mm) PSD range (m) R5 500 4.5-875 R6 1000 9.0-1759 R7 2000 18-3500

[0137] Water Activity

[0138] Water activity was measured using a standard dew point measurement on an Aqualab 3TE series, manufactured by Labcell Ltd, UK) as described below: [0139] 1The Aqualab instrument was calibrated using the water activity standards of 0.250 and 0.500 prior to each measurement to ensure accurate calibration of the instrument before each measurement. [0140] 2A sample of powder as mixed gently by hand to ensure it was in a free-flowing state and a small amount of sample added to a sample cup such that the powder covers the bottom of the cup in a thin layer. [0141] 3The sample cup was placed to the drawer of the Aqualab 3TE instrument and allowed to equilibrate to ambient temperature. [0142] 4Once the equilibration was reached, a water activity reading was given by the instrument.

[0143] The chocolate powder of Example 2, according to the invention, produced by the continuous agglomeration process, showed a reduction in bulk density and improved flowability with a reduction in the Hausner's ratio compared to the control chocolate powder. Further, the D50 of the continuously agglomerated chocolate powder was higher than that of control chocolate powder and the Q90 (amount of fines) significantly reduced to about 14%, from 27% in the control chocolate powder, resulting in an increase in porosity of around 0.1.

[0144] By these parameters the chocolate powder according to the invention, made by continuous agglomeration, showed better flowability, lower level of fines, higher median particle size and increased porosity over standard chocolate powder.

Example 3: Use of the Chocolate Powder According to the Invention, of Example 2, in Preparation of a Beverage

[0145] 30 g of the chocolate powder according to the invention, made by continuous agglomeration, was packed into a commercial Tassimo Big T-disc at a volume of 53.2 ml (88% fill volume) and chocolate powder residues measured and compared to an identical Tassimo Big T-disc packed with 30 g of control chocolate powder at a volume of 46 ml (76% fill volume) in a range of Tassimo beverage preparation machines.

[0146] The range of Tassimo machines are all capable of reading barcodes located on the T-discs (or any other capsule, pod, container, etc.) in order to adjust the brewing parameters of the machine such as water flow rate, temperature, etc., in accordance with information read from the barcode.

[0147] The range of Tassimo machines provided water heated to between 85 and 95 C. and drink weight of 160 ml to 235 ml

[0148] Chocolate powder residues were significantly reduced across the range of all machines tested, as shown in FIG. 3. For each pair of results the right-hand, shorter line is the control. Residue was calculated as the percentage of chocolate powder remaining in the disc after the brew cycle had been completed.

Example 4: 2.SUP.nd .Embodiment of a Chocolate Powder of the Invention

[0149] A 2.sup.nd control chocolate powder characterized by 36% fines and a bulk density of 690 g/l had a poor residue of 38% after brewing.

[0150] The 2.sup.nd control chocolate powder was then processed by the continuous agglomeration process of Example 1 to become a 2.sup.nd agglomerated chocolate powder according to the invention.

[0151] The 2.sup.nd agglomerated chocolate powder according to the invention showed properties of significantly lower level fines (11%) and lower bulk density (550 g/l) than that of the 2.sup.nd control.

[0152] The 2.sup.nd agglomerated chocolate powder of the invention and the 2.sup.nd control chocolate powder were then added to respective Tassimo Big T-discs and both were prepared in a Tassimo Chassis 6 machine.

[0153] The resultant, used, Big T-discs showed that there was a significant reduction in chocolate residue in the disc that contained the 2.sup.nd chocolate powder according to the invention vs the disc that had contained the 2.sup.nd control chocolate powder after brewing: 37% residue with the 2.sup.nd control and 8% residue with the 2.sup.nd chocolate powder according to the invention; as shown in FIG. 2.

[0154] Further the 2.sup.nd agglomerated chocolate powder according to the invention, after continuous agglomeration, had lower water activity than the 2.sup.nd control chocolate powder, before processing. The second chocolate powder according to the invention had a water activity of 0.37 compared to the 2.sup.nd control chocolate powder water activity of 0.48.

[0155] The low water activity (<0.37) of the agglomerated chocolate powder maintains low residue in the disc, after brewing, over time compared to the 2.sup.nd control.

Example 5: Optimising Powders of the Invention for Improved Shelf-Life

[0156] A 3rd agglomerated chocolate powder of the invention with a water activity of 0.59, median particle size (D50) of 338 microns, fines level (Q90) of 3.7% and density of 420 g/l was brewed in a Tassimo Chassis 6 brewer yielding residue of 4%.

[0157] The 3.sup.rd agglomerated chocolate powder of the invention was further processed in an agglomerator of Example 1 to produce an Improved agglomerated chocolate powder of the invention, with improved shelf-life.

[0158] The Improved agglomerated chocolate powder of the invention, with improved shelf life, had a water activity of 0.33, median particle size (D50) of 295 microns, fines level (Q90) of 5.3% and a density of 486 g/l.

[0159] Both powders were placed in a shelf life cabinet of 23 C. at 55% Relatively Humidity (RH) and each month, water activity and residue after preparation in a standard Chassis 6 machine, were measured.

[0160] As shown in FIG. 4a: At 9 months shelf life the 3.sup.rd agglomerated chocolate powder of the invention had a water activity of 0.61; whereas the Improved agglomerated chocolate powder of the invention with improved shelf life had a water activity level of 0.378.

[0161] As shown in FIG. 4b: At 9 months shelf life the 3.sup.rd agglomerated chocolate powder of the invention yielded a residue of 31.7%; whereas the Improved chocolate powder of the invention with improved shelf life yielded a residue of 0.2%. FIGS. 4a and 4b show the performance of both chocolate powders over a 9-month shelf life and that the Improved chocolate powder of the invention with improved shelf life was further optimised for performance over the shelf life of the product.

Example 6: Dairy Creamer

[0162] A 6.2 g of a Control dairy creamer comprising 64% skimmed milk powder, 27.5% sugar and 8.25% Cream powder (total fat of 7.9%) was packed into a standard Senseo filter pod. When used in a standard Senseo Original beverage preparation machine it had a solubility of 75% (25% residue left in the pod after use).

[0163] The Control dairy creamer was then agglomerated in a batch process to produce an agglomerated Dairy creamer of the invention. The batch agglomeration process differed from the continuous agglomeration process of Example 1 in the following ways: [0164] The wetting, drying and cooling steps were all performed in the same zone of the batch agglomerator [0165] The batch process started with filling the batch agglomerator with beverage ingredient powder and finished with emptying the batch agglomerator of the beverage ingredient powder

[0166] The batch agglomerator was a Strea-1 agglomerator, manufactured by GEA. During processing the beverage ingredient powder temperature was maintained below 45 C. and the total residence of the powder in the agglomerator was kept below 30 mins.

[0167] The physical properties of the Control dairy creamer were improved in the Dairy creamer according to the invention, after continuous agglomeration, as follows: [0168] The Control dairy creamer had D50 of 198 microns, whereas the Diary creamer according to the invention, after continuous agglomeration had D50 of 293 microns [0169] The Control dairy creamer had a fines content (Q90) of 23% whereas the Dairy creamer according to the invention, after continuous agglomeration had Q90 of 5%. [0170] The Control dairy creamer had a bulk density of 508 g/l, whereas the Dairy creamer according to the invention, after continuous agglomeration had a bulk density of 465 g/l

[0171] When used in the standard Senseo Original beverage preparation machine, the solubility of the Dairy creamer according to the invention, after agglomeration, went up to 90% (10% residue left in the pod after use).

Example 7High Shear Agglomerated Powder

[0172] 11.5 g of a control dairy powder comprising 75% whole milk powder and 25% icing sugar (19.5% wt total fat, 440 g/l bulk density, median particle size (D50) of less than 100 microns and fines level (Q90) of 26.8%) was packed into standard Tassimo disc to create a control dairy powder T-disc.

[0173] An agglomerated dairy powder of the invention was created from the control dairy powder by adding the Second control dairy powder into a mixer and set to mix by an impeller mounted on a vertical axis at between 180 and 125 RPM to create high shear throughout processing. The powder was then wetted with a liquid binder (water) sprayed through a nozzle at a rate of 30 g/min for 10 minutes. The powder was then subjected to fluid bed drying with heated air for 35 minutes such that the powder temperature was maintained below 50 C. The resultant powder had a bulk density of 800 g/l.

[0174] The powder was then milled and passed through a 0.8 mm sieve to yield an agglomerated diary powder of the invention with bulk density of 700 g/l, water activity of below 0.37, D50 particle size of 710 microns and Q90 of <5%. Without wishing to be bound by theory, the inventors believe that the 0.8 mm sieve is important to the working of the invention as particles over 1 mm contribute to lower solubility of the powder, particularly when used in conjunction with beverage preparation machines that work at relatively low pressure (i.e. pressures below about 5-10 bar).

[0175] 18 g of the agglomerated dairy powder of the invention was packed into a standard Tassimo disc to create a Second dairy powder T-disc of the invention.

[0176] Both T-disc were brewed in a Tassimo T20 machine and the residue left in the discs after preparation was measured.

[0177] The control dairy T-disc yielded a residue in the disc after brew of 12% of the 11.5 g of control powder loaded into the disc before brewing.

[0178] The agglomerated dairy powder T-disc of the invention yielded a residue in the disc after brew of 4% of the 18 g of powder of the invention loaded into the disc before brewing.

[0179] The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims.