System and method for preparing compostable capsules from paper material for beverage preparation

Abstract

The present invention relates to a system (100) for preparing compostable capsules (900) for brewing products. Wherein the capsule (900) is made of a sheet (600) made of a biodegradable cellulose-based material. The system (100) comprises at least one forming line (200) comprising a handling unit (300) for conveying a sheet (600) through the system (100) in a conveying direction (TD). The forming line (200) further comprises a humidification unit (400) for wetting at least one side of the sheet (600) with a wetting agent (401), and a forming unit (800) for forming a portion of the wetted sheet (600) into a three-dimensional shape to form an encapsulation element (910) defining an encapsulation cavity (911). The portion (642) is located between opposite lateral side edge sections (631, 632) of the sheet (600) with respect to the transport direction (TD). The forming line (200) further comprises a transverse drying unit (500) arranged to dry the opposite transverse side edge sections (631, 632) of the wet sheet (641) while keeping at least the portion (642) to be formed wet. Wherein the transverse drying unit (500) is arranged downstream of the humidifying unit (400) and upstream of the forming unit (800). The invention also relates to a method for preparing a compostable capsule (900) in which the opposite lateral side edge sections (631, 632) of a wet sheet (641) are dried while at least the portion (642) to be formed is kept wet prior to forming the portion (642) of the wet sheet (641).

Description

1. Technical Field

[0001] The present invention relates to a system and method for preparing a compostable capsule for an infused product, wherein the capsule is prepared from a sheet made of a biodegradable cellulose-based material. 2. Background technology

[0002] Single-serve beverage containers (such as capsules or pods) for beverage preparation machines are known in the art. These beverage containers are typically used to dispense beverages on demand, such as coffee, tea or hot chocolate, and are popular due to the fresh taste, variability of flavor and convenience of beverage preparation.

[0003] Typically, these known beverage containers are made of materials that are challenging to reuse, recycle or compost, particularly after use of the beverage container. Therefore, efforts are made to replace these established materials with biodegradable or compostable materials (such as cellulose-based materials, such as paper), for which the process of disposing of the used beverage container (e.g., via composting) is less challenging.

[0004] The use of new materials for beverage containers also requires new manufacturing processes. For example, in industrial production, beverage containers made of cellulose-based materials can be produced from a continuous (continuous) sheet of paper material that travels through different stations of a production line. At one station, a section of the sheet is formed into a half shell and then filled with a beverage component, such as coffee, before being sealed closed using another half shell or a lid.

[0005] Among other things, it has been found that wetting the sheet before forming the half shells can benefit the structural integrity and shelf life of the resulting beverage container, as the half shells may tear or split due to mechanical stresses during the forming process. These effects can be avoided or even eliminated by wetting the sheet before performing the forming step. An example of a manufacturing process that implements such a wetting process can be found in WO 2020 / 031096 A1.

[0006] During the wetting process, water is applied to the entire surface of the sheet to ensure that the moisture is evenly distributed. The disadvantage of such a treatment is that the sections of the sheet that will not undergo forming will also be wetted and exposed to the liquid. However, this may lead to the undesirable side effect of curling of the sheet. For example, cellulose-based sheet materials generally include hollow fibers that absorb water, which will cause the diameter of the fibers to expand, but not the length. As a result, mechanical tension will accumulate inside the sheet material, which may cause the sheet to curl or wrinkle. In the case of a sheet material with a directional component, that is, most of the fibers of the sheet material are aligned and oriented in a specific direction, this effect may be even further exacerbated. In addition, sheet materials for beverage containers generally include multiple layers, such as barrier layers. When in contact with water, each layer may produce a different reaction (e.g., expansion), resulting in curling of the sheet.

[0007] Unfortunately, in cellulose-based sheet materials, the effects of curling are difficult to reverse. In particular, exposing the sheet to water may cause the fibers to align in a different manner, or may release inherent tensions in the material that may recover after drying the sheet, causing the (originally flat) sheet to curl.

[0008] This material property can cause problems during the manufacturing process of beverage containers:

[0009] For example, the portion of the beverage container that is destined for connection with a closure element used to close and seal (and then dry and fill) the beverage container typically does not undergo forming and is therefore susceptible to curling due to a lack of structural support during the manufacturing process. However, this can compromise the connection between the closure element and the beverage container, as curling can result in inadequate contact, gaps and channels leading to the interior of the beverage container. As a result, the integrity and quality of the beverage container cannot be ensured during such a process, thereby limiting the shelf life of the product within the beverage container.

[0010] Additionally, conveying and manipulating sheet materials during the manufacturing process can become more difficult because mechanical properties such as tensile strength or tear resistance are reduced in wet sheets compared to dry sheets. As a result, dragging or pushing sheets through the production line can become more challenging.

[0011] In the prior art, the above problems are solved by fixing the sheet material in a strong frame and letting it dry slowly over time. Unfortunately, this known solution cannot be applied to the industrial manufacturing process of beverage containers, where a continuous process is preferably used to obtain high circulation rates.

[0012] Therefore, it is an object of the present invention to provide a system and method for preparing a pouch made of compostable material, by which the structural integrity and shelf life of the pouch produced can be improved and ensured. Among others, it is a particular object of the present invention to reduce or eliminate the risk of curling of the sheet material, in particular in sections that will not undergo forming. Furthermore, it is an object of the present invention to reduce or even eliminate the risk of tearing of the sheet material during the manufacturing process.

[0013] These and other objects which become apparent after reading the description are solved by the subject-matter of the independent claims.The dependent claims relate to preferred embodiments of the invention. 3. Summary of the invention

[0014] A first aspect of the present invention relates to a system for preparing a compostable capsule for an infused product. The system is (configured / adapted) for preparing a capsule from a sheet made of a biodegradable cellulose-based material.

[0015] The term "capsule" may be understood as any (closed) container (e.g., capsule) for preparing a beverage in a beverage production machine, for example. For example, beverage preparation may include dissolving, brewing, or percolating a substance enclosed in the capsule to produce a brewed product, such as coffee, tea, fruit drink, or cooking broth.

[0016] The term "sheet" may be understood as, for example, a large, thin, flat piece of material. For example, the sheet may be a paper sheet material supplied in a dry state, i.e. with a maximum level of (relative) moisture or humidity in the range of 2% to 8%, preferably 5%. However, the level of (relative) moisture or humidity depends on the ambient conditions.

[0017] In addition, the term "compostable" may be understood to mean that when material is composted, it can be decomposed into organic matter (mainly water, CO2 (or methane) and biomass) in a few weeks or months. This can be done in industrial composting sites and / or household composters. Such locations may have specific conditions related to temperature and relative humidity. Other conditions may also affect composting, such as wind, sunlight, drainage and other factors. At the end of the composting process, once the material is fully decomposed, nutrients can be supplied to the land. International standards (such as, EU 13432 or US ASTM D6400) provide a legal framework for the technical requirements and procedures for determining the compostability of materials. In contrast, "biodegradable" materials may be understood to be any material that can be decomposed into environmentally friendly products by organisms (such as microorganisms, for example bacteria, fungi or algae) (effect). This process can be carried out in an environment where there is or is not oxygen (aerobic / anaerobic).

[0018] The system includes at least one forming line.

[0019] Therein, the expression "forming line" may be understood as a system or arrangement, for example, capable of performing (sequentially) various functions or operations involved in the capsule production (manufacturing) process, which may preferably be interconnected (to produce compostable capsules with reliable and high structural integrity).

[0020] The forming line comprises a handling unit for conveying the sheet material through the system along a conveying direction. The forming line further comprises a humidifying unit for moistening at least one side of the sheet material with a moistening agent.

[0021] Therein, the expression "humidifying unit" may be understood as a component of, for example, a forming line, which is capable (or configured) for bringing (applying or introducing) a wetting agent (liquid, gas, solution) into or onto the sheet. To this end, the wetting agent may be applied directly to the sheet, or a carrier medium (e.g. ambient air) may be moistened or dampened by a humidifying unit, which may transfer moisture to the sheet. A "wetting agent" may be, for example, any substance or liquid, such as water or any aqueous solution, which may preferably be suitable for reducing the inherent rigidity of the sheet material of the capsule used for the forming step.

[0022] The forming line further comprises a forming unit for forming a portion of the wet sheet material into a three-dimensional shape to form a padding element defining a padding cavity.

[0023] Therein, the term "shaped" may be understood as, for example, utilizing the formability, extensibility and / or flexibility of the material to change its (three-dimensional) shape (with or without the support of additional tools and / or preferably with or without the application of heat). Furthermore, the term "wetted" may be understood as, for example, that the sheet material is subjected to (and the sheet material preferably carries a certain amount of) a wetting agent and that the wetting agent is present in the material.

[0024] In this application, the terms "moist" and "humid" and the terms "moisten" and "humidify" are used interchangeably.

[0025] The portion of the sheet is located between opposite lateral side edge sections of the sheet with respect to the conveying direction.

[0026] Therein, the expression “lateral side edge section” may be understood as, for example, a region, part or component of a sheet, which may, for example, extend longitudinally together with a (lateral) side edge of the sheet and / or may extend laterally towards a corresponding opposite side edge of the sheet.

[0027] The at least one forming line further comprises a transverse drying unit arranged downstream of the humidifying unit and upstream of the forming unit. The transverse drying unit is arranged (configured) to dry the opposite transverse side edge sections of the wet sheet while keeping at least the portion to be formed wet.

[0028] Therein, the expression "drying unit" is to be understood as a device or a station for reducing or removing the (liquid or gaseous) content of (foreign) substances contained in or on the surface of the sheet material, preferably by evaporation and / or by supplying energy for evaporating the substance.

[0029] In other words: According to the present invention, a preparation system capable of producing compostable capsules from cellulose-based sheet materials can be provided.

[0030] For this purpose, a handling unit is provided, by means of which the sheet can be conveyed (transported, moved, dragged, transported) (linearly) through the system. Furthermore, a humidifying unit is provided, by means of which a (liquid and / or gaseous) wetting agent can be (uniformly) applied to at least one side of the sheet. A drying unit is provided, by means of which sections of the wet sheet that will not undergo forming can be (re)dried, but sections that will undergo forming to form a capsule are not dried. For forming, a forming unit is provided, by means of which a capsule element (or a part of a capsule body or at least a part of a capsule) can be formed from the wetted sections of the sheet.

[0031] This configuration of the preparation system is advantageous in avoiding damage to the integrity of the capsule that would affect the forming or wetting process, since the sheet can be provided with localized dry sections (e.g. for sealing or manipulation) and wet sections (for forming), thereby making the two contradictory states of the sheet compatible with each other. This is because a device is provided for promoting localized and controlled drying, which can be customized (e.g. in terms of physical area, duration and / or strength) for the respective application (e.g. the dry patch used, the size and position of the sheet material). Thus, the connection area for sealing and closing the capsule can be provided in a manner that will not curl, and the material elasticity required for conveying the sheet can be maintained throughout the process. At the same time, since only local drying is performed in the system, the capsule is still formed with a wet sheet. In addition, the system of the present invention is conducive to continuous manufacturing, thereby leading to high productivity, because the operations can be carried out in sequence without interruption.

[0032] Therefore, the system of the present invention overcomes the shortcomings of the prior art.

[0033] According to a preferred embodiment, the handling unit may comprise (one or more) clamping elements. Preferably, the clamping elements may be configured to clamp the sheet at opposite (with respect to the conveying direction) lateral side edge sections of the sheet. Alternatively or in addition, the clamping elements may be movable in the conveying direction. Preferably, the clamping elements may be configured to clamp the sheet at opposite lateral side edge sections, so that the clamped sheet can be conveyed through the system in the conveying direction.

[0034] Therein, the expression “clamping element” may be understood as an element, for example, for fixing, attaching, compressing and / or holding a sheet (preferably between two opposing elements, components, structures and / or parts).

[0035] Thus, the sheet can be continuously conveyed through the system and held under tension along its longitudinal extension. Thus, production can be carried out in a particularly advantageous manner.

[0036] According to a preferred embodiment, the transverse drying unit may be arranged to dry the opposite transverse side edge sections of the moistened sheet before or during clamping by the clamping elements, while keeping at least the portion to be formed moistened. Preferably, the transverse drying unit may be arranged between a feed section for feeding the sheet into the system and the clamping elements.

[0037] Thereby, it can be ensured that the sheet is clamped after (only) the moisture contained in the interior of the sheet has been removed or reduced by the drying unit.

[0038] According to a further preferred embodiment, the transverse drying unit may comprise a drying component, such as a hot air blower and / or a heating element. For example, the heating element may be configured for contact drying or contactless drying (e.g., infrared (IR) or ultraviolet (UV) radiation, such as emitted by an infrared dryer or an ultraviolet dryer). Preferably, the transverse drying unit may be integrated with the clamping element. For example, the clamping element may comprise a heating element.

[0039] Therein, the expression “contact drying” is to be understood as meaning, for example, a drying process in which the element to be dried can be brought into contact with a heated surface (so that the energy required for drying can be transported into the material by conduction).

[0040] Thus, it is possible to ensure that drying is carried out locally within a specific time. For example, some sheet materials require rapid evaporation of water so that they can remain flat and wrinkle-free after wetting, and the above-mentioned drying unit can achieve rapid evaporation of water. It is particularly advantageous that drying parameters, such as the flow rate and temperature of the drying medium, and / or the distance between the drying element and the sheet, can be easily and accurately adjusted using the above-mentioned drying unit.

[0041] Preferably, the drying component can be configured to achieve fast drying within, for example, 0.1 s. More preferably, the drying component can be configured preferably according to one or more of the following drying parameters: drying temperature, speed and / or volume of air flow, direction of air flow.

[0042] For example, drying may be performed within a "drying time span" (e.g. lasting from the start until a defined (reduced) moisture content is reached) between 0.5 s and 20 s. The drying time span may depend on the thickness of the sheet, the type of sheet material used and / or the moisture content (humidity level) at the start of the drying process. Preferably, the transfer speed of the sheet may be between 1 cm / s and 100 cm / s.

[0043] Therein, the expression "humidity level" (moisture content) may be understood as a numerical quantification of the main liquid substance (or moisture and / or humidity) contained in the sheet material, for example. For example, it is conceivable that the moisture level may be an indication of the (liquid and / or gaseous) moisture content in paper and / or the relative humidity of the (paper) sheet material. Therein, the moisture content (or moisture content) may be understood as the amount of (liquid and / or gaseous) water contained in a solid material (e.g. measured by weight in grams). It is clear from this that in the present description, unless explicitly stated otherwise, the terms "moisture" and "humidity" may be used interchangeably.

[0044] For example, the moisture level (moisture content) can be expressed as absolute humidity. For example, the liquid (wetting agent) content in a material can be expressed as weight / volume (g / m 3 ) measurement. Alternatively or in addition, the moisture level (moisture content) can be expressed as relative humidity. For example, the liquid content can be measured as the ratio between the measured humectant content and the maximum amount of liquid content that can be absorbed by the material (e.g., a ratio expressed as a percentage).

[0045] Preferably, the dry sheet may have a maximum (relative) level of moisture or humidity in the range of 2% to 8%, preferably 5%. In contrast, the wet sheet may have a (relative) level of moisture or humidity in the range of 9% to 40%, preferably 12% to 20%, more preferably 14% to 16%.

[0046] More preferably, the drying component can be configured to dry between 1 mm 2 Up to 30cm 2 Preferably, the drying area can be dried within the drying time span defined above. Preferably, the (vertical) "distance between the drying component and the sheet" can be between 1 cm and 50 cm.

[0047] Preferably, the "width of each of the transverse side edge sections" may be in the range between 1% and 10%, preferably in the range between 2% and 5%, of the width of the sheet (extending between the two transverse side edges of the sheet and / or preferably measured orthogonally to the longitudinal extension of the sheet). For example, the width of the sheet may be the length of a reel from which the sheet may be provided.

[0048] However, these are only examples, not a complete list, and the drying parameters may include additional other parameters.

[0049] According to a preferred embodiment, the humidifying unit may be arranged to wet only one side of the sheet.Preferably, the humidifying unit may be arranged to wet only the lower side of the sheet, for example if the sheet can be conveyed horizontally through the humidifying unit.

[0050] By applying the wetting agent on the underside of the sheet, it is ensured that the wetting agent fully penetrates the sheet material, while the excess liquid is automatically drained away by being drawn out of the material under the action of gravity. Thus, local deviations in moisture concentration caused by the humidification process can be reduced.

[0051] According to another preferred embodiment, the humidifying unit may include an immersion unit for immersing at least one side of the sheet material in a wetting agent. Alternatively or in addition thereto, the humidifying unit may include a spraying unit for spraying the wetting agent onto at least one side of the sheet material. Alternatively or in addition thereto, the humidifying unit may include a (cold) steam unit for applying the wetting agent to at least one side of the sheet material. Alternatively or in addition thereto, the humidifying unit may include a roller conveying unit for conveying the wetting agent from a reservoir onto at least one side of the sheet material. For this purpose, for example, one or two rollers may be provided to convey the liquid onto the sheet material. In each of the above-mentioned configurations, the wetting agent may be provided in a liquid state and / or in a gaseous state.

[0052] Thus, the wetting agent can be applied to the sheet material in various ways.

[0053] According to a further preferred embodiment, the at least one forming line may further comprise at least one humidity sensor for (visually) sensing the humidity level of the wet sheet. Preferably, the humidity sensor may be constructed and / or arranged to sense the humidity level at at least one side of the sheet. For example, the at least one humidity sensor may be positioned downstream of the humidifying unit and / or upstream of the forming unit with respect to the conveying direction. For example, the humidity sensor may emit light in the visible spectrum and measure the reflectivity of the radiation to determine the humidity level.

[0054] Thereby, the amount, location and extent of the wetting agent within the sheet can be determined with high accuracy and high sampling speed. This enables the wetting process in the humidifying unit to be adjusted. Thus, the structural integrity and shelf life of the produced pods can be improved and ensured.

[0055] According to a preferred embodiment, the at least one forming line may further comprise a pre-drying unit for drying the sheet before reaching the forming unit. Preferably, the pre-drying unit may be constructed and / or arranged for drying at least a portion of the sheet, which portion may preferably be on at least one side.

[0056] Thereby, the moisture content contained in the wet section of the sheet can be reduced before reaching the forming unit. Wherein, the control of the pre-drying unit can be adjusted based on the measurement results of the moisture sensor so that the wet section of the sheet can be formed in the forming unit with an optimal moisture level.

[0057] According to a preferred embodiment, the system or at least one forming line may further comprise a final drying unit for drying the capsule element. According to a further preferred embodiment, the system (or at least one forming line) may further comprise a filling unit for placing a certain amount of brewing material in the capsule cavity of the capsule element. The filling unit may preferably be arranged downstream of the final drying unit with respect to the conveying direction.

[0058] The brewing material may be any type of (solid, liquid, at least partially soluble and / or percolatable) substance having a specific or well-defined chemical composition. Examples of such substances may be roasted ground coffee, instant coffee, tea leaves, concentrated syrups, concentrated fruit extracts, chocolate products, dehydrated edible substances such as freeze-dried broth for cooking, and / or combinations thereof.

[0059] Thereby, the pad element can be dried before reaching the filling unit, so that the pad is filled with brewing material in a dry state, which is beneficial to the shelf life of the pad.

[0060] According to a preferred embodiment, the system (or at least one forming line) may further comprise a joining unit for joining a closing element to a capsule element to close a capsule cavity (preferably around a certain amount of said brewing material). Preferably, the closing element may be a lid. Alternatively, the closing element may be another capsule element. Therein, the capsule elements may be joined such that their cavities together form a closed capsule cavity. Furthermore, the system may comprise two forming lines, each forming line being used to form a capsule element, and the joining unit being used to join two capsule elements to form a capsule cavity.

[0061] Thus, a physical (and preferably sealed) connection can be provided between the capsule element and the corresponding closure element. The connection can be achieved by heat sealing or ultrasonic sealing. Thus, an airtight closure or encapsulation of the brewing material can be provided within the capsule cavity. Thus, the integrity and shelf life of the capsule can be ensured.

[0062] According to another preferred embodiment, the sheet can be a continuous sheet. The continuous sheet can be provided from a reel. To this end, the system (or more specifically: the manipulation unit) can also preferably include a conveying unit for unwinding the sheet. For example, the sheet can be longitudinally extended in a continuous manner. In addition, the sheet can preferably be adapted to be connected to other such sheets at the end sections to form a seemingly "continuous" sheet in the production process.

[0063] Thereby, the sheets can be provided in a manner which is particularly suitable for industrial production. In particular, sequential and continuous processing can be improved.

[0064] According to a preferred embodiment, the sheet may have gas barrier properties.

[0065] Gas barrier can be understood as the ability of a material to reduce or eliminate the passage of gaseous substances through the sheet (material). For example, the sheet can have an oxygen transmission rate (OTR) of less than 5 cm 3 / m 2 / day oxygen barrier. Among them, OTR can be a measure of the amount of oxygen passing through a material within a defined period of time. For example, OTR can be measured using known methods specified in industrial standards, such as DIN 53380-3, ASTM D1434 or ISO 2872.

[0066] The sheet material may have a single-layer structure made of a cellulose-based material having gas barrier properties. Alternatively, the sheet material may have a multi-layer structure including a paper layer and a barrier layer. The paper layer may be made of a cellulose-based material. Preferably, the paper layer may form at least one side of the sheet material and / or one side of the lower side of the sheet material. The barrier layer may have gas barrier properties.

[0067] By providing the sheet with a gas barrier, the shelf life of the pouch can be improved.

[0068] Another aspect of the present invention relates to a method for preparing a compostable capsule for brewing products. The method comprises the step of conveying a sheet made of a biodegradable cellulose-based material and preferably having gas barrier properties through a system along a conveying direction. At least one side of the sheet is moistened with a wetting agent. A portion of the moistened sheet is formed into a three-dimensional shape to form a capsule element defining a capsule cavity. The portion is located between opposite lateral side edge sections of the sheet relative to the conveying direction. Prior to forming the portion of the moistened sheet, the method further comprises the step of drying the opposite lateral side edge sections of the moistened sheet while keeping at least the portion to be formed moistened. The formed capsule element can (then) be (filled and) dried.

[0069] All definitions and effects described above for the system are also applicable to the method of the present invention. The system is suitable for performing the method.

[0070] According to the above configuration of the method, a compostable capsule can be provided from a sheet material, which has a high and reliable structural integrity and shelf life. This is possible because the liquid content at the area of ​​the sheet that is relevant to the integrity of the final capsule and the transport of the sheet can be reduced by the method.

[0071] According to a preferred embodiment, the method may further comprise the step of clamping the sheet at the transverse side edge sections to preferably convey the clamped sheet in a conveying direction. Wherein, the clamping may be performed after or during drying the opposite transverse side edge sections. Alternatively or in addition, the clamping may be performed during forming a portion of the wet sheet. The step of conveying the sheet may be a process of conveying the clamped sheet in a conveying direction.

[0072] Thus, the sheet material can be efficiently and reliably conveyed through the forming line. In addition, the sheet material can be handled carefully enough and has sufficient strength, thereby improving the preparation of the pads.

[0073] According to a further preferred embodiment, the method may further comprise the step of placing a quantity of brewing material in the capsule cavity of the capsule element. According to a preferred embodiment, the method may further comprise a joining step, in which a closing element may be joined to the capsule element to close the capsule cavity. The joining step may preferably comprise joining a lid as a closing element, or joining another capsule element as a closing element. In the latter case, the capsule elements may preferably be joined such that their cavities together form a closed capsule cavity.

[0074] Thus, a capsule with beverage ingredients can be provided and sealed from the outside.Therefore, the capsule can have a longer shelf life. 4. Description of the drawings

[0075] When reading the following detailed description of embodiments of the invention in conjunction with the accompanying drawings, additional features, advantages and objects of the invention will become apparent to the skilled person. Where numbers are omitted from the drawings, for example for clarity, corresponding features may still be present in the drawings.

[0076] Figure 1 A schematic side view of a production system having a forming line according to an embodiment of the present invention is shown.

[0077] Figure 2 Shown is a schematic cross-sectional side view of a pad made using systems and methods according to further embodiments of the invention.

[0078] Figure 3 Shown is a schematic cross-sectional side view of a pad made using systems and methods according to further embodiments of the invention. 5. Specific implementation methods

[0079] Figure 1 Various aspects of embodiments of a system 100 and method for preparing a compostable pod 900 for an infused product according to the present invention are shown. Figure 2 and Figure 3Aspects of various embodiments of a compostable pod 900 prepared using the system 100 and method according to the present invention are shown.

[0080] The system 100 is configured for preparing a compostable pod 900 from a sheet material 600 . Figure 1 The system 100 and some components of the system are shown by way of example. Figure 2 and Figure 3 An example of a pad 900 that may be produced using the system 100 is shown.

[0081] The sheet 600 is made of a biodegradable cellulose-based material. For example, the cellulose-based material may include cellulose fibers, paper, paperboard, cellulose pulp for molding, cellulose nanofiber sheets or films, air-laid cellulose and / or delignified wood. The material of the sheet 600 can provide a barrier to moisture and / or gas. To this end, the sheet 600 may have a single layer structure, such as a cellulose-based material, which is thick enough or configured to provide a gas barrier. Figure 1 and Figure 3 The use of a sheet 600 having a single layer is exemplarily shown. Alternatively, the sheet 600 may have, for example, a multi-layer structure having a paper layer 611 made of a cellulose-based material and a barrier layer 612 having a gas barrier property. The barrier layer 612 may be provided inside or outside the pouch 900 . Figure 2 The use of such a material configuration of the sheet 600 is shown by way of example.

[0082] For the purpose of industrially preparing the pouch 900, the sheet 600 may be provided, for example, as a continuous sheet. This type of sheet 600 may be provided from a reel, and the system 100 may comprise a conveying unit (not shown) for unrolling the sheet 600 from the reel and for introducing the sheet 600 into the system 100. However, it is also conceivable that the sheet 600 is provided as a separate blank sheet. Preferably, the sheet 600 may have a thickness between 10 microns and 5 millimeters, more preferably between 50 microns and 800 microns, even more preferably between 100 microns and 500 microns. More preferably, the sheet 600 may extend longitudinally between two opposite side edges 603, 604. Thus, the sheet 600 may extend transversely between the two side edges 603, 604. The sheet 600 may have an upper side 602 and a relatively lower side 601 (e.g., a directional reference for the sheet 600 being transported horizontally). Figure 1 This is shown by way of example.

[0083] The system 100 includes at least one forming line 200 . Figure 1An embodiment of a forming line 200 is shown by way of example. For example, the forming line 200 may include a series of stations, each providing a function required to prepare a pouch 900. For example, a section of the sheet 600 may pass through each station in a sequential order. The system 100 may include one or more forming lines 200.

[0084] The forming line 200 comprises a handling unit 300 for conveying the sheet 600 through the system 100 along a conveying direction TD. Figure 1 This is shown by way of example.

[0085] For example, the manipulation unit 300 may include a manipulation element, such as a clamping element 310. The clamping element 310 may be configured to clamp the sheet material 600 at opposite lateral side edge sections 631, 632 of the sheet material 600 (with respect to the conveying direction TD). Figure 1 This is shown exemplarily.For example, each of the transverse side edge sections 631 , 632 may be a continuous (relatively thin) strip of the sheet 600 , which may preferably extend longitudinally with the side edges 603 , 604 of the sheet 600 .

[0086] The clamping element 310 may be arranged to be movable in the conveying direction TD. By operating the clamping element 310, the sheet 600 may be clamped at the opposite lateral side edge sections 631, 632 and moved by the clamping element 310. The clamped sheet 600 may be conveyed through the system 100 in the conveying direction TD.

[0087] However, other embodiments of the manipulation unit 300 can be envisioned. For example, the manipulation unit 300 can be one or two rollers that can be arranged relative to each other with respect to the sheet 600 so as to drive the sheet 600 forward by rotating relative to each other. However, it is also conceivable that the manipulation unit 300 can be provided as a conveyor belt or a pusher. Additional manipulation elements (such as rollers) of the manipulation unit 300 can be arranged at various positions along the conveying direction TD to ensure that the sheet 600 is reliably transported through the system 100. Preferably, the sheet 600 can be moved linearly along the conveying direction TD. The sheet 600 can be moved horizontally (such as horizontally) within the system 100. Figure 1 shown) or transported vertically (not shown).

[0088] The forming line 200 further includes a humidifying unit 400 for moistening at least one side of the sheet 600 using a moistening agent 401 . Figure 1 An exemplary embodiment of a humidifying unit 400 is shown.

[0089] like Figure 1As shown, the humidifying unit 400 may include a roller conveying unit 410 for conveying the wetting agent 401 from a reservoir 411 to at least one side of the sheet 600. For example, the wetting agent 401 may be applied to the lower side 601 of the sheet 600 by means of a roller 461, wherein preferably, the roller 461 may be at least partially immersed in the wetting agent 401. The roller 461 may then come into contact with the sheet 600, and thereby the wetting agent 401 may be brought into the sheet material within a defined section of the sheet 600, which may be referred to as a wetting section 641 of the sheet 600. For example, the water content in the wetting section may be higher than the water content in the rest of the sheet 600 (e.g., the section before the roller 461). Preferably, the humidifying unit 400 may be arranged to wet only one side of the sheet 600. This is particularly useful in Figure 1 4 , in which only the lower side 601 of the sheet 600 can be wetted by the humidifying unit 400. As a result, excess liquid can leave the lower side 601 and can return to the reservoir 411. However, it is also conceivable that the upper side 602 and / or the lower side 601 can be wetted.

[0090] In addition, other embodiments of the humidifying unit 400 are conceivable, which will be briefly discussed below: For example, the humidifying unit 400 may include an immersion unit for immersing at least one side of the sheet 600 in the wetting agent 401. Alternatively or in addition, the humidifying unit 400 may include a spraying unit for spraying the wetting agent 401 onto at least one side of the sheet 600. Alternatively or in addition, the humidifying unit 400 may include a (cold) steam unit for applying the wetting agent 401 to at least one side of the sheet 600.

[0091] Preferably, the sheet 600 may be provided in the system 100 so that the barrier layer 612 may be arranged on the opposite side of the humidifying unit 400, for example, in order to facilitate sufficient absorption of the humidifying agent 401 during the humidification process. In other words, the paper layer 611 may preferably be at least one side and / or the lower side 601 of the sheet 600. However, this is only an example.

[0092] The wetting agent 401 may be water, a water-based solution, or an alcohol-based solution (such as ethanol, methanol, isopropanol, or butanol). The water-based solution may also contain trace amounts of inorganic salts, such as sodium, magnesium, calcium, and potassium.

[0093] The forming line 200 further comprises a forming unit 800 for forming the portion 642 of the wet sheet 641 into a three-dimensional shape, forming a capsule element 910 defining a capsule cavity 911. Figure 1 In the figure, the forming unit 800 is exemplarily indicated.

[0094] Figure 2 and Figure 3An exemplary embodiment of a capsule element 910 is shown, from which it can be seen that, for example, the body of the capsule 900 can be formed by the capsule element 910. Figure 2 and Figure 3 As further exemplarily shown in FIG. 9 , the padding element 910 may thereby define a padding interior having a padding cavity 911 . For example, the padding element 910 may be a formed portion 642 of the wet sheet 641 .

[0095] The forming unit 800 forms the portion 642 between opposite lateral side edge sections 631 , 632 of the sheet 600 with respect to the conveying direction TD. The forming unit 800 may comprise forming tools such as a forming die and a movable corresponding die for forming the padding element 910 having the padding cavity 911 .

[0096] At least one forming line 200 further comprises a transverse drying unit 500. The transverse drying unit 500 is arranged to dry the opposite transverse side edge sections 631, 632 of the wet sheet 641 while keeping at least the portion to be formed 642 wet. Figure 1 It can also be seen from the figure that the transverse drying unit 500 can be arranged downstream of the humidifying unit 400 and upstream of the forming unit 800.

[0097] For example, the transverse drying unit 500 may include a drying component such as a hot air blower and / or a heating element 510 for drying. Figure 1 This is shown exemplarily. It is also conceivable that the transverse drying unit 500 may be integrated with the clamping element 310 and that the clamping element 310 may therefore comprise a heating element 510 .

[0098] In the case where the clamping elements 310 can be used to convey the sheet 600 through the system 100, the transverse drying unit 500 can be arranged to dry the opposite transverse side edge sections 631, 632 of the wet sheet 641 before or during clamping by the clamping elements 310 (while keeping at least the portion 642 to be formed wet). To this end, the transverse drying unit 500 can be arranged between a feeding section for feeding the sheet 600 into the system 100 (not shown) and the clamping elements 310.

[0099] The forming line 200 may further include a moisture sensor 700 for visually sensing the moisture level of the wet sheet 641. Thus, the wet sheet may be inspected by the moisture sensor 700 (continuously in time and space). Figure 1A humidity sensor 700 is schematically shown. Preferably, the humidity sensor 700 can sense the humidity level at a section of the sheet 600, which section can at least partially correspond to the portion 642 for forming in the forming unit 800. The humidity sensor 700 can sense a section of the sheet 600 at at least one side of the sheet 600. Figure 1 As exemplarily shown in FIG. 1 , at least one humidity sensor 700 may be positioned downstream of the humidifying unit 400 and preferably upstream of the forming unit 800 relative to the conveying direction TD. Preferably, the humidifying unit 400 and the humidity sensor 700 may be arranged on opposite sides relative to the sheet 600, such as Figure 1 For example, the moisture sensor 700 may include an optical instrument, such as a (high resolution) camera, to capture a visual image of at least the wet section 641 showing the moisture level of the sheet 600 .

[0100] The forming line 200 may further include a control unit 390 configured to receive values ​​related to the humidity level sensed by the humidity sensor 700 and control the humidifying unit 400 and the transverse drying unit 500 based on the values. The control unit 390 may be configured to compare the received values ​​with a defined reference value and control the humidifying unit 400 based on the comparison between the received values ​​and the defined reference value.

[0101] For example, the sheet 600 may be considered to have a good moisture content, wherein the (relative) moisture content or humidity level of the sheet material is in the range of 9% to 40%, preferably 12% to 18%, and more preferably 12% to 16%. However, the present invention is not limited to these values, as they may vary depending on the respective sheet material.

[0102] Preferably, the control unit 390 can be configured to control and / or adjust a number of different parameters and components of the forming line 200. For example, the control unit 700 can be configured to adjust the travel speed of the sheet 600, the composition of the wetting agent 401, the travel speed of the clamping element 310 and / or the temperature of the forming tools in the forming unit 800. The control unit 390 is preferably connected to all elements of the forming line 200. For the manipulation unit 300, the forming unit 800, the transverse drying unit 500 and the moisture sensor 700, the information links (connections) between the corresponding components are Figure 1 However, this also applies to the humidifying unit 400 and / or other components described below:

[0103] For example, the system 100 may further include a pre-drying unit for drying the sheet 600 before reaching the forming unit 800. Preferably, at least the wet portion 641 of the sheet 600 may be dried by the pre-drying unit. Alternatively or in addition, the system 100 may further include a final drying unit for drying the capsule element 910. Alternatively or in addition, the system 100 may further include a filling unit for placing a certain amount of brewing material 990 in the capsule cavity 911 of the capsule element 910. Therein, for example, the filling unit may be arranged downstream of the final drying unit with respect to the conveying direction TD. However, it is also conceivable that the filling unit may be part of the forming unit 800. Alternatively or in addition, the system 100 may include a joining unit for joining a closing element 950 to the capsule element 910 to close the capsule cavity 911 around the certain amount of brewing material 990.

[0104] Figure 2 and Figure 3 Various examples of embodiments of the closure element 950 are shown. For example, the closure element 950 may be a cover 951 such as Figure 2 Alternatively, the closing element 950 may be another capsule element 910, wherein preferably the capsule elements 910, 910 may be joined so that their cavities 911 together form a closed capsule cavity 911. To this end, it is conceivable that the system 100 may be provided with two forming lines 200, each forming line for forming the capsule element 910, and further provided with the joining unit for joining the two capsule elements 910, 910.

[0105]

[0066] Additional aspects of the invention relate to methods for making compostable pods, such as pod 900 described above. Figures 1 to 3 The steps of the method are shown.

[0106] For example, in this method, a sheet made of a biodegradable cellulose-based material and preferably having gas barrier properties, such as the sheet 600 described above, is conveyed through the system 100 along a conveying direction TD. Figure 1 This is shown by way of example.

[0107] Among them, preferably, the method may include the step of clamping the sheet 600 at the lateral side edge section of the sheet 600 to convey the clamped sheet 600 along the conveying direction TD.

[0108] At least one side of the sheet 600 is wetted with a wetting agent, such as the wetting agent 401 described above. Figure 1 This is exemplarily shown on an example where the humidifying unit 400 is a roller conveying unit 410 .

[0109] The moisture level of at least one section of the wet sheet 600 , such as the wet section 640 , may be visually sensed so that a value related to the sensed moisture level may be received. Figure 1 This is shown by way of example by moisture sensor 700 , which emits light for measuring the moisture content of at least wet section 641 .

[0110] The portion 642 of the wet sheet 641 is formed into a three-dimensional shape to form a capsule element defining a capsule cavity, such as the capsule element 910 described above with the capsule cavity 911. The portion 642 is located between the opposite lateral side edge sections 631, 632 of the sheet 600 with respect to the conveying direction TD. Figure 1 The position and geometry of portion 642 are shown exemplarily. Figure 2 and Figure 3 Possible results of the forming (shaping) step are shown exemplarily.

[0111] It is contemplated that the padding element 910 is dried after forming. However, the padding element 910 may be dried at various other stages in the overall manufacturing process.

[0112] The wetting process (step) of at least one side of the sheet 600 may be controlled based on the values ​​obtained in the visual sensing step. For this purpose, for example, a control unit 390 may be used. The control unit 390 may be configured to control and / or provide the process steps of the method.

[0113] Prior to forming the portion 642 of the wet sheet 641 , the opposite lateral side edge sections 631 , 632 of the wet sheet 641 are dried while at least the portion 642 to be formed is kept wet. Figure 1 This is exemplarily shown by the transverse drying unit 500 which may be configured to blow hot air or radiation onto the wet sheet 641 to dry the transverse side edge sections 631 , 632 without drying the portion to be formed 641 .

[0114] Preferably, the conveying step may mean conveying the clamped sheet 600 along the conveying direction TD. Wherein, clamping may preferably be performed after or during drying the opposite lateral side edge sections 631, 632. Alternatively or in addition, clamping may be performed during forming the portion 642 of the wet sheet 641.

[0115] The method may include the step of placing a quantity of brewing material, such as brewing material 990 described above, in cavity 911 of pad member 910 . Figure 2 and Figure 3 A filled bladder is shown exemplarily.

[0116] The method may also include the step of joining a closure element (such as closure element 950 described above) to the bladder element 910 to close the cavity 911. Figure 2 and Figure 3 For example, the joining step may include joining a cover such as a cover 951 as a closure element 950 to the capsule element 910. Alternatively, another capsule element 910 may be joined as a closure element 950. Thus, the capsule elements 910 may be joined so that their cavities 911 together form (one) closed capsule cavity 911.

[0117] The invention is not limited to the embodiments described herein above, as long as it is covered by the accompanying claims.All features of the embodiments described above may be combined in any possible way and provided interchangeably.

Claims

1. A system (100) for preparing a compostable capsule (900) for infusion products from a sheet (600) made of a preferably biodegradable cellulose-based material, the system (100) comprising at least one forming line (200), the at least one forming line comprising: a manipulating unit (300) for conveying the sheet (600) through the system (100) along a conveying direction (TD); A humidifying unit (400) for moistening at least one side of the sheet (600) using a moistening agent (401); and a forming unit (800) for forming a portion (642) of the moistened sheet (641) between opposite lateral side edge sections (631, 632) of the sheet (600) relative to the conveying direction (TD) into a three-dimensional shape to form a capsule element (910) defining a capsule cavity (911); The at least one forming line (200) further comprises: ● A transverse drying unit (500), which is arranged to dry the opposite transverse side edge sections (631, 632) of the wet sheet (641) while keeping at least the portion (642) to be formed moistened, and is located downstream of the humidifying unit (400) and upstream of the forming unit (800).

2. A system (100) according to claim 1, wherein the manipulation unit (300) includes a clamping element (310), and wherein the clamping element (310) is configured to clamp the sheet (600) at the relative lateral side edge sections (631, 632) of the sheet (600) relative to the conveying direction (TD).

3. A system (100) according to claim 2, wherein the clamping element (310) is capable of moving along a conveying direction (TD), and wherein the clamping element (310) is configured to clamp the sheet (600) at the relative lateral side edge sections (631, 632) of the sheet (600) relative to the conveying direction (TD), thereby enabling the clamped sheet (600) to be conveyed along the conveying direction (TD) through the system (100).

4. A system (100) according to claim 2 or claim 3, wherein the transverse drying unit (500) is arranged to dry the relative transverse side edge sections (631, 632) of the wet sheet (641) before or during clamping by the clamping element (310) while keeping at least the portion (642) to be formed moistened, wherein preferably, the transverse drying unit (500) is integral with the clamping element (310).

5. A system (100) according to any of the preceding claims, wherein the transverse drying unit (500) comprises a hot air blower and / or a heating element (510), wherein preferably, the clamping element (310), if present, comprises the heating element (510).

6. The system (100) according to any one of the preceding claims, wherein the transverse drying unit (500) is arranged between a feeding section for feeding the sheet (600) into the system (100) and the clamping element (310).

7. A system (100) according to any of the preceding claims, wherein the humidifying unit (400) is arranged to wet only one side of the sheet (600), preferably the lower side (601) of the sheet (600), when the sheet (600) is preferably conveyed horizontally through the humidifying unit (400).

8. The system (100) according to any one of the preceding claims, wherein the humidifying unit (400) comprises at least one of the following: o an immersion unit, the immersion unit being used to immerse the at least one side of the sheet material (600) into the wetting agent (401), o a spraying unit, the spraying unit being used to spray the wetting agent (401) onto the at least one side of the sheet (600), o a steam unit, preferably a cold steam unit, for applying the wetting agent (401) to the at least one side of the sheet (600), o A roller conveying unit (410) for conveying the wetting agent (401) from a reservoir (411) to the at least one side of the sheet (600).

9. The system (100) according to any one of the preceding claims, wherein the at least one forming line (200) further comprises at least one of the following: o a pre-drying unit for drying the sheet (600) before reaching the forming unit (800), preferably for drying at least a portion of the sheet (600), o at least one humidity sensor (700) for sensing the humidity level of the wet sheet (641), preferably at said at least one side of said sheet (600), wherein preferably said at least one humidity sensor (700) is positioned downstream of said humidifying unit (400) and preferably upstream of said forming unit (800) with respect to said conveying direction (TD), o a final drying unit for drying the capsule element (910), a filling unit for placing a quantity of brewing material (990) in the capsule cavity (911) of the capsule element (910), wherein the filling unit is preferably arranged downstream of the final drying unit, if present, with respect to the conveying direction (TD), o A joining unit for joining a closing element (950) to the pad element (910) to close the pad cavity (911), preferably around the quantity of brewing material (990).

10. The system (100) of claim 9, wherein the closure element (950) is ● Cover (951), or • Another padding element (910), wherein preferably said padding elements (910) are joined such that their cavities together form a closed padding cavity (911).

11. The system (100) of claim 10, wherein the system (100) comprises: two said forming lines (200), each forming line being used to form a padding element (910), and A joining unit, which is used to join two pad elements (910) to form the pad cavity (911).

12. The system (100) according to any one of the preceding claims, wherein the sheet (600) is a continuous sheet, and / or wherein the sheet (600) has gas barrier properties, Preferably, the sheet (600) has a single-layer structure made of a cellulose-based material having the gas barrier property if present, or Preferably, the sheet (600) has a multi-layer structure, and the multi-layer structure comprises: o a paper layer (611) made of a cellulose-based material, the paper layer (611) preferably forming said at least one side of the sheet (600) and / or forming the underside of the sheet, and o A barrier layer (612) having the gas barrier properties if present.

13. A method for preparing a compostable capsule (900) for brewing a product, the method comprising: • conveying a sheet (600) made of a biodegradable cellulose-based material, preferably having gas barrier properties, through the system (100) along a conveying direction (TD); ● Wetting at least one side of the sheet (600) using a wetting agent (401); shaping a portion (642) of the wetted sheet (641) between opposite lateral side edge sections (631, 632) of the sheet (600) relative to the conveying direction (TD) into a three-dimensional shape to form a capsule element (910) defining a capsule cavity (911); • preferably drying the encapsulation element (910); The method further comprises: ● Drying the opposite lateral side edge sections (631, 632) of the wet sheet (641) before forming the portion (642) of the wet sheet (641) while keeping at least the portion (642) to be formed wet.

14. The method according to claim 13, further comprising: ● clamping the sheet (600) at the transverse side edge sections (631, 632) of the sheet (600) to preferably convey the clamped sheet (600) along the conveying direction (TD), ○ wherein preferably, clamping is performed after or during drying of the opposite transverse side edge sections (631, 632), and / or o wherein preferably, clamping is performed during forming of said portion (642) of said wet sheet (641), and / or ○ Preferably, the conveying step includes conveying the clamped sheet (600) along the conveying direction (TD).

15. The method according to claim 13 or 14, further comprising the following steps: ● placing a certain amount of brewing material (990) in the capsule cavity (911) of the capsule element (910), • Joining a closure element (950) to the bladder element (910) to close the bladder cavity (911), wherein the joining step preferably comprises: o engaging a cover (951) as said closure element (950), or o Engaging another capsule element (910) as the closing element (950), wherein preferably the capsule elements (910) are joined such that their cavities (911) together form a closed capsule cavity (911).

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