Method and packaging machine for manufacturing a compostable pod for brewing products and compostable pod for brewing products

Abstract

A method for manufacturing a compostable pod for brewing products envisages preparing a first and a second sheet made of biodegradable material with gas barrier properties, shaping the first and the second sheet so as to make at least a first and a second concave portion, filling the first concave portion with a predetermined quantity of brewing product and joining the first concave portion to the second concave portion so that the respective concavities are opposite one another and define a casing for the brewing product. The shaping steps of the first and the second sheet envisage moistening at least a first portion of the first sheet and a second portion of said second sheet, configuring the first and the second portion so as to make the first and the second concave portion and drying the first and the second concave portion.

Claims

1. A method for manufacturing a compostable pod for brewing products, the method comprising: preparing a first sheet and a second sheet made of biodegradable material with gas barrier properties; shaping the first sheet to make at least a first concave portion; shaping the second sheet to make at least a second concave portion; after shaping the first concave portion and the second concave portion, filling the first concave portion with a predetermined quantity of brewing product; joining the first concave portion to the second concave portion so that the respective concavities are opposite one another and define a casing for the brewing product; the shaping steps of the first sheet and of the second sheet comprising: moistening at least a portion of the first sheet and a portion of the second sheet; after moistening the portion of the first sheet and the portion of the second sheet, configuring the portion of the first sheet and the portion of the second sheet to make the first concave portion and the second concave portion; and after configuring the portion of the first sheet and the portion of the second sheet, drying the first concave portion and the second concave portion, wherein the drying is carried out by a heating member configured to dry the first concave portion and the second concave portion so that concave configurations of the first concave portion and the second concave portion is maintained, the biodegradable material comprises a plurality of superimposed layers comprising (i) a non-woven fabric comprising at least 40% biodegradable fibres by weight of the non-woven fabric and (ii) a layer of adhesive suitable for contact with foodstuffs.

2. The method according to claim 1, wherein the drying step comprises heating the first concave portion and the second concave portion simultaneously or following the configuring step.

3. The method according to claim 1, wherein the moistening step comprises directing at least one steam flow at a predetermined temperature against the portion of the first sheet and the portion of the second sheet.

4. The method according to claim 3, wherein each of the first sheet and the second sheet has two different faces; the moistening step being carried out by directing two different steam flows against the two different faces of each of the first sheet and the second sheet.

5. The method according to claim 1, wherein the configuring step comprises moving a shaping body comprising at least one convex stamp towards and away from a concave mould with a mutually complementary shape.

6. The method according to claim 1, wherein the biodegradable fibres in the non-woven fabric are at least 40% by total weight of the biodegradable material.

7. The method according to claim 1, wherein the biodegradable material comprises vegetable parchment.

8. The method according to claim 1, wherein the adhesive is acrylic.

9. The method according to claim 1, wherein the biodegradable fibres are selected from the group consisting of polylactic acid (PLA), polyhydroxyalkanoates (PHA); poly-?-hydroxybutyrate (PHB); polyhydroxybutyrate-co-hydroxyvalerate (PHBV); polybutylene succinate (PBS); biopolyester; and cotton, linen and wood fibres.

10. The method according to claim 1, wherein the non-woven fabric integrates barrier properties and is capable of reducing gas permeability.

Description

(1) These and other characteristics, together with their respective advantages, will be more apparent from the exemplary, and therefore non-limiting, description that follows of a preferred, and therefore non-exclusive, embodiment of a machine and of a method for manufacturing a compostable pod for brewing products according to what is shown in the accompanying figures, wherein:

(2) FIG. 1 shows a schematic vertical perspective view of a packaging machine for manufacturing a compostable pod for brewing products according to the present invention;

(3) FIG. 2 shows a schematic vertical perspective view of a shaping station for the packaging machine in FIG. 1;

(4) FIGS. 3A and 3B show a side view of a pod 1 00 manufactured with the packaging machine in FIG. 1 and a single preformed concave portion manufactured with the shaping station in FIG. 2.

(5) With reference to the accompanying figures, reference numeral 1 denotes a packaging machine used to implement the method for manufacturing a compostable pod for brewing products according to the present invention.

(6) The machine 1, as well as the manufacturing method implemented thereby, are therefore intended for use in the manufacture and production of single-use compostable pods, of the type used to prepare beverages, primarily hot beverages, by brewing or percolation.

(7) In general, the pod 100 is an element composed of a first concave portion 2a and a second concave portion 3a which are joined together so that the respective concavities are opposite one another and define a casing inside which a predetermined quantity of brewing product is placed.

(8) It should be noted that the pods 100 manufactured with the machine and the method according to the present invention may differ in type and may contain a wide variety of brewing products, such as coffee (preferred), tea, herbal teas, and the like.

(9) From a procedural point of view, first of all a first 2 and a second sheet 3 of biodegradable material with gas barrier properties are prepared.

(10) The term sheet is used here to define any flexible element having a planar extension and two-level faces opposite one another.

(11) It should be noted that the term sheet is used to encompass both elements having a clearly-defined planar extension as well as rolls of material wherein the length of the material is much greater than its width.

(12) The spirit of the invention is meant to encompass both in line solutions and more stationary solutions, in which single sheets of material are processed discreetly.

(13) The first 2 or the second sheet 3 of biodegradable material with gas barrier properties is preferably made of a composite material having a cellulosic component and a biopolymeric or bioplastic component.

(14) Said material has absolutely no fossil or petroleum-derived content and can therefore be considered wholly compostable or biodegradable in accordance with even the strictest requirements of national legislation.

(15) According to a preferred embodiment, the biodegradable material with gas barrier properties has a basis weight of between 90 and 150 grams.

(16) Preferably, the biodegradable material with gas barrier properties comprises a plurality of superimposed layers, including one or more of the following: a non-woven fabric comprising at least 40% biodegradable fibres by weight, and preferably by total weight; a layer of adhesive that is suitable for coming into contact with foodstuffs and, in any case, less than 5% by weight of the material; a barrier medium capable of reducing gas permeability, such as vegetable parchment or the like.
The biodegradable fibres used may be chosen, for instance, from a group containing: PLA (polylactic acid), PHA (polyhydroxyalkanoates); PHB (poly-p-hydroxybutyrate); PHB(V) (poly hydroxybutyrate-co-hydroxyvalerate); PBS (polybutylene succinate); biopolyester; cellulosic fibres such as cotton, linen and wood fibres.

(17) The adhesive layer, if present, is preferably of the acrylic type.

(18) The method for manufacturing the pod 100 must generally comprise a step of shaping the first 2 and the second sheet 3 so as to make the first concave portion 2a on the first sheet 2 and the second concave portion 3a on the second sheet 3.

(19) Preferably, a succession of first concave portions 2a are made on the first sheet 2 and a corresponding succession of second concave portions 3a are made on the second sheet 3.

(20) It should be noted that, such shaping steps may be performed simultaneously or in successive steps, in a same station or in different stations, without in any case departing from the spirit of the present invention.

(21) According to the invention, said steps of shaping the first 2 and the second sheet 3 envisage moistening at least a first portion of said first sheet 2 and a second portion of said second sheet 3.

(22) Preferably, the humidification or impregnation of the portions of the sheets 2, 3 is performed by directing at least one steam flow at a predetermined temperature against the first and said second portion.

(23) Alternatively, however, the humidification step could be performed using other methods. For example, the humidification step could be performed by nebulising a liquid (e.g. demineralised water) on the sheet 2, 3 or by impregnating the sheet 2, 3 using specific devices (baths, rollers, sponges).

(24) According to the preferred embodiment, the step of moistening the first or the second portion is performed by directing two separate steam flows, which can preferably be controlled and adjusted separately, against the two faces of each first 2 or second sheet 3.

(25) Advantageously, this allows the different layers of biodegradable material with gas barrier properties to be impregnated in different ways.

(26) The shaping step further involves configuring the first and the second portion so as to make the first 2a and the second concave portion 3a.

(27) In other words, the previously moistened portion of the first 2 and of the second sheet 3 is configured, for example by means of a punch, stamp or the like.

(28) Advantageously, in this way the cellulosic fractions of the material are more malleable and the risk of breakage is considerably reduced, while maintaining production speeds compatible with the cycle times required to meet the demands of today's market.

(29) Following, or at the same time as the configuration process, the first 2a and the second concave portion 3a are dried.

(30) In other words, the drying step involves heating the first 2a and the second concave portion 3a, at the same time as or following said shaping step, in order to crystallise the shape of the material that has been obtained.

(31) The concave portions 2a, 3a obtained from the shaping step are then used to manufacture the pod 100.

(32) In particular, the first concave portion 2a is filled with a predetermined quantity 4 of brewing product, which, as already mentioned, may vary in type.

(33) Lastly, the first concave portion 2a, filled with said quantity 4, is joined to the second concave portion 3a so that the respective concavities are opposite one another and define a casing for said brewing product.

(34) Therefore, advantageously, the method that is the subject of the invention allows you to manufacture a pod 100 wherein both the first 2a and the second concave portion 3a are preformed and made of biodegradable material with gas barrier properties.

(35) This method is implemented, for example, with the packaging machine 1 that is the subject of the invention.

(36) This machine 1 comprises one or more shaping stations 5, 6, a filling station 7 and a joining station 8.

(37) In particular, the machine 1 comprises a first shaping station 5 and a second shaping station 6.

(38) The first shaping station 5 is configured to provide the first sheet 2 of biodegradable material provided with said first concave portion 2a, preferably with a succession of first concave portions 2a.

(39) The second shaping station 6 is configured to provide the second sheet 3 of biodegradable material provided with said second concave portion 3a, preferably with a succession of second concave portions 3a.

(40) It should be noted that the first 5 and the second shaping station 6 could be arranged within one device and could act simultaneously on the two sheets 2, 3, or they could be physically separate, without in any case departing from the spirit of the invention.

(41) Each shaping station 5, 6 comprises a feeding unit 9 of the respective first 2 or second sheet 3 of biodegradable material with gas barrier properties.

(42) This feeding unit 9 is configured to feed the sheet 2, 3 (or the strip) along a direction of travel A.

(43) Along said direction of travel A there is a humidification device 10 for humidifying at least a portion of the respective first 2 or second sheet 3.

(44) Preferably, the humidification device 10 comprises at least one steam generator 10a configured to generate a steam flow V hitting the respective portion of the first 2 or second sheet 3.

(45) According to the preferred embodiment, the humidification device 10 comprises two steam generators 10a arranged opposite one another, each directed towards a respective face of the first 2 or second sheet 3.

(46) These steam generators 10a can preferably be controlled separately, to enable the differentiation and optimisation of the impregnation of each face of the sheet 2, 3.

(47) Alternatively, however, other humidification systems could be used, such as nebuliser/spray nozzles or applicator rollers (e.g. with brushes or sponges).

(48) Operationally downstream of the humidification device 10 there is a configuration device 11.

(49) The configuration device 11 comprises at least one shaping body 12 and heating means 13.

(50) The shaping body 12 is configured to give the impregnated portion of the sheet a concave configuration.

(51) The heating means 13 are, instead, configured to dry said portion so that said concave configuration is maintained.

(52) According to the preferred embodiment, the shaping body 12 comprises at least one stamp 12a (convex) able to move towards and away from a mould 12b (concave) with a mutually complementary shape.

(53) In this way the portion of the first 2 or of the second sheet 3 is given its concave configuration.

(54) Preferably, the heating means 13 comprise a heating body 13a connected to said stamp 12a and/or to said mould 12b in order to dry the concave portion 2a, 3a of the first 2 or second sheet 3 during the configuration.

(55) Preferably, the heating body 13a is defined by at least one element incorporated in the stamp 12a or in the mould 12b.

(56) According to the preferred embodiment, the shaping body 12 is configured to exert a compressive force of between 1000 and 3000 N.

(57) The heating body 13a is, instead, preferably configured to increase the temperature of the stamp 12a or of the mould 12b to a temperature of between 50 and 130? C. during the configuration step.

(58) Advantageously, in this way the accurate configuration of the concave portions 2a, 3a is achieved quickly and reliably.

(59) The invention achieves its intended purposes and significant advantages are thus obtained.

(60) The filling station 7 comprises a dispensing device 7a, of a type known in the prior art and therefore not described in detail here. The dispenser 7a may be of the type for dispensing pre-set weights or volumes, or of the timed type, without in any case departing from the spirit of the invention.

(61) The joining station 8 may, in turn, vary in type. Preferably, an ultrasound welding device 8a (sonotrode) is used to avoid or limit the presence of adhesive.

(62) However, a heat sealer or other system known in the prior art could easily be used instead.

(63) Indeed, given the consecutive nature of the humidification and drying steps, with the shaping step performed between these, the risks of fractures and breaks in the biodegradable material, which is ill-suited to dry forming owing to its cellulosic components, are reduced to a minimum.

(64) Moreover, performing the drying step during configuration means that the exact configuration is maintained, facilitating the subsequent steps of filling and joining and freeing the manufacturer from the need to use suction or vacuum systems to maintain such shape.