Ready-to-eat freeze-dried coffee making technology and device and freeze-dried coffee made through technology and device

Abstract

The invention relates to the technical field of freeze-dried coffee, in particular to an instant freeze-dried coffee making process and device and freeze-dried coffee made through the instant freeze-dried coffee making process and device. The process comprises the following steps: S1, dissolving and sterilizing: stirring and dissolving all raw materials, performing shearing emulsification after stirring, performing sterilization after supplementing water to a constant volume, and cooling to room temperature to obtain a liquid sample; s2, mold pouring: injecting a liquid sample into a mold, discharging bubbles through equipment vibration, and scraping the surface of the mold after pouring by using a scraper; s3, pre-freezing and demolding: freezing the material, and separating and demolding the material from the mold after the material is maintained at a set temperature; s4, secondary pre-freezing: putting the demolded material into a freezing bin for freezing; and S5, vacuum drying: after pre-freezing is completed, starting a vacuum pump, starting vacuum drying, and keeping drying. And S6, discharging and packaging: after vacuum drying is completed, taking out the materials, packaging and sealing. The freeze-dried coffee is ready to eat, and the original fragrance and nutritional value of coffee are highly reserved.

Description

Technical Field

[0001] This application relates to the field of freeze-dried coffee technology, and in particular to a process, apparatus and the freeze-dried coffee produced from ready-to-eat freeze-dried coffee. Background Technology

[0002] Traditional instant coffee often uses thermal processing techniques such as spray drying, which easily leads to the loss of a large amount of volatile aroma compounds during production. Furthermore, high temperatures can damage the original flavor components of coffee, resulting in a product with a monotonous flavor and poor quality. In addition, with the increasing consumer demand for functional foods, functional coffee products fortified with vitamins and minerals have emerged on the market. However, these heat-sensitive active ingredients are easily degraded and deactivated during traditional high-temperature drying processes, significantly reducing their functional effects.

[0003] While existing technologies employ freeze-drying to better preserve flavor, ordinary freeze-dried coffee products are brittle and fragile, making them inconvenient to carry and use. Furthermore, their relatively simple formulations make it difficult to effectively protect multiple heat-sensitive functional components while simultaneously achieving flavor synergy and texture optimization. In particular, ensuring high retention rates and stability of highly temperature- and shear-sensitive active substances such as probiotics, slow-release encapsulated compounds, and plant extracts during industrial production remains a pressing technical challenge. Therefore, developing a ready-to-eat freeze-dried coffee product that simultaneously offers excellent flavor, instant consumption, and specific functional activities is of significant practical importance. Summary of the Invention

[0004] This application provides a process, apparatus, and freeze-dried coffee production method for ready-to-eat coffee to solve the above-mentioned problems.

[0005] In one aspect, this application provides a ready-to-eat freeze-dried coffee comprising, by weight percentage: 1-40% coffee, 3-16% fat powder, 1-8% dietary fiber, 3-12% carbohydrates, and at least one active ingredient, with the remainder made up to 100% with purified water.

[0006] Through the above technical solution, the original aroma, active ingredients (such as polyphenols and caffeine), and nutritional value of coffee are highly preserved by low-temperature vacuum freeze-drying, avoiding degradation caused by traditional heat processing. The synergistic effect of fat powder and dietary fiber forms a uniform porous structure, giving the product rapid oral solubility and ensuring its ready-to-eat nature, while reducing the hygroscopicity of the freeze-dried blocks. The introduction of active ingredients expands the product's health benefits, such as energizing, antioxidant, and anti-fatigue properties, and the wide range of formulation ratios allows for adjustments based on market demand (such as low-sugar, high-fiber, or specific functional versions). This formulation is highly compatible with subsequent processes, ensuring batch-to-batch consistency and the feasibility of large-scale production.

[0007] Optionally, the active ingredients include sustained-release caffeine and plant antioxidants; The sustained-release caffeine content is 0.5-10%, and the sustained-release caffeine is encapsulated using microencapsulation technology; The plant antioxidant is green tea extract, with a content of 0.1-5%, used to construct a dual-effect matrix of energizing and antioxidant properties.

[0008] Through the above technical solutions, microencapsulation significantly improves the retention rate of caffeine during processing and achieves sustained-release properties in vivo for 4-6 hours, providing a stable and lasting energizing experience while avoiding discomfort such as rapid heartbeat. Green tea extract retains high antioxidant activity after freeze-drying, providing consumers with clear health benefits and helping to combat daily oxidative stress. The "slow-release energizing effect" and "continuous antioxidant effect" complement each other functionally, working together to improve the body's energy level and health status, forming a product competitiveness of 1+1>2. The microcapsule structure effectively masks the bitterness of caffeine and protects green tea polyphenols from oxidative browning, improving the product's sensory attributes and shelf-life appearance.

[0009] Optionally, the active ingredient further includes an adaptogen, which is Rhodiola Rosea extract at a content of 0.1-3%, for anti-stress and anti-fatigue functions.

[0010] Through the aforementioned technical solutions, the product is transformed from merely stimulating the nervous system into a functional food that helps users manage daily stress and improve overall endurance and mental resilience. Slow-release caffeine (acting on adenosine receptors), Rhodiola Rosea (regulating the HPA axis and neurotransmitters), and green tea extract (antioxidant) work synergistically through different physiological pathways, achieving a comprehensive benefit greater than the sum of its parts (1+1+1>3). The user experience shifts from simply "from drowsy to alert" to an overall improvement in well-being, moving from fatigue and stress to abundant energy. The introduction of scientifically backed and in high-demand adaptogens significantly enhances the product's technological content and market competitiveness, meeting the needs of specific groups such as those engaged in high-intensity mental work and students. Thanks to the low-temperature characteristics of the freeze-drying process, heat-sensitive bioactive components in Rhodiola Rosea are efficiently preserved, ensuring the product's intended functions.

[0011] Optionally, the active ingredient further includes probiotics or prebiotics, wherein the probiotics are Lactobacillus or Bifidobacterium, and the content is 10. 6 -10 9 CFU / g, wherein the prebiotic is fructooligosaccharide or inulin derivative, and its content is 1-5%.

[0012] Through the aforementioned technical solutions, the product has been upgraded from a simple energy-boosting food to a functional food that also supports gastrointestinal health, satisfying consumers' pursuit of "inside and out" health. Thanks to precise additive processes and freeze-drying protection, the number of live bacteria in the product remains stable within the promised range at the time of manufacture. Furthermore, through in vitro simulated gastrointestinal fluid testing, a significant proportion of the strains have been verified to be resistant to gastric acid and bile salts, successfully reaching the intestines. The presence of prebiotics significantly improves the survival rate and colonization ability of exogenously supplemented probiotics, enabling them to establish a dominant flora in the intestines more quickly, inhibiting harmful bacteria, and thus more effectively regulating the balance of intestinal flora. While retaining the energy-boosting, stress-relieving, and antioxidant functions of coffee, the added dimension of intestinal health greatly broadens the product's target audience and market appeal, making it especially suitable for consumers who are concerned about digestive health and immunity.

[0013] Optionally, the coffee includes one or more of the following: coffee extract, coffee concentrate, instant coffee powder, freeze-dried coffee powder, or ground coffee powder. The fat powder includes one or more of coconut oil powder, medium-chain triglyceride powder, butter powder, or cocoa powder; The dietary fiber includes one or more of inulin, resistant dextrin, polydextrose, or fructooligosaccharides; The carbohydrates include one or more of sucrose, glucose, trehalose, xylitol, or sorbitol.

[0014] The above technical solutions effectively mask the unpleasant flavors introduced by various functional ingredients, transforming the product from a "functional medicine" to a "delicious and enjoyable food," greatly enhancing consumers' eating pleasure. All ingredients are natural and derived from plants, aligning with the trend towards clean labeling. The freeze-drying process effectively "freezes" the flavor, ensuring the complete preservation of heat-sensitive natural aroma compounds. When the product is rehydrated, the porous structure of the freeze-dried block promotes the rapid and uniform release of flavor compounds, achieving an "instant aroma" effect.

[0015] Secondly, this application provides a process for making ready-to-eat freeze-dried coffee, the process comprising: S1. Dissolving and sterilizing: Dissolve all raw materials in water at 65-75℃ by stirring for 10-20 minutes, then emulsify by shearing at 3000-10000 rpm for 10-20 minutes, add water to make up the volume, sterilize, and cool to room temperature to obtain a liquid sample. S2, Mold casting: The liquid sample is injected into the mold, the air bubbles are expelled by the vibration of the equipment, and the surface of the mold is smoothed by a scraper after casting. S3. Pre-freezing and demolding: Keep the material frozen in an environment of -20℃ to -45℃ for 5 to 12 hours. After the material is kept at the set temperature for 1 to 3 hours, separate the material from the mold. S4. Secondary pre-freezing: Place the demolded material in a freezer for freezing, maintaining the freezing temperature at -45℃ to -80℃ for 1-3 hours; S5. Vacuum drying: After pre-freezing is completed, start the vacuum pump and begin vacuum drying, maintaining the drying process for 20-60 hours.

[0016] S6. Unloading and Packaging: After vacuum drying is completed, the material is removed and sealed in packaging.

[0017] Through the aforementioned technical solutions, freeze-dried blocks with specific densities and porosities possess optimal structural strength, effectively resisting impacts and pressures during transportation and ensuring the product arrives at the consumer intact. The combination of high-barrier packaging materials and nitrogen-filled / vacuum technology constructs a robust barrier, effectively blocking moisture, oxygen, and light, providing full-cycle protection for core functional ingredients (such as probiotic activity and the stability of the slow-release system) and coffee flavor from manufacturing to consumption. Individual packaging ensures hygiene, precision, and convenience for each consumption. The regular shape of freeze-dried blocks offers superior visual appeal compared to powders, while their rapid rehydration properties provide a seamless mixing experience. The freeze-drying process ensures that various components in the slurry are "locked" within the microstructure of the freeze-dried blocks, avoiding the component separation problems that may occur with powdered products and ensuring the consistency of efficacy and flavor in every serving.

[0018] Optionally, in the vacuum drying step, the retention rate of active ingredients is optimized by controlling the pre-freezing rate and vacuum level, wherein the pre-freezing rate is 1-5℃ / min and the vacuum level is 0.1-1Pa.

[0019] Through the above technical solutions, the homogeneous slurry formed by viscosity control produces a fine, loose, porous structure after freeze-drying. This results in a product with satisfactory crispness, rapid dissolution in the mouth to release flavor, and avoids an unpleasant gritty or sticky feeling. Effective degassing and viscosity control fundamentally reduce product defects (such as bubbles and cracks), significantly improving the production yield.

[0020] Optionally, in the mold casting step, the mold is designed as a mini cubic or sheet shape, and the shape and texture of the freeze-dried coffee are controlled by adjusting the slurry viscosity to 100-500 cP.

[0021] Through the above technical solutions, the homogeneous slurry formed by viscosity control produces a fine, loose, porous structure after freeze-drying. This results in a product with satisfactory crispness, rapid dissolution in the mouth to release flavor, and avoids an unpleasant gritty or sticky feeling. Effective degassing and viscosity control fundamentally reduce product defects (such as bubbles and cracks), significantly improving the production yield.

[0022] Optionally, in the dissolution and sterilization step, the active ingredients are added in the following order: First, dissolve the fat powder and dietary fiber, then add coffee and carbohydrates, and finally add the active ingredients to avoid the degradation of heat-sensitive ingredients; The active ingredients include slow-release caffeine, green tea extract, Rhodiola Rosea extract, probiotics or prebiotics, and the probiotics are added when cooled to below 30°C to maintain their activity.

[0023] Using the above technical solution, this segmented addition strategy can maintain the survival rate of probiotics at 10%. 8 -10 9 The high CFU / g level ensures a high retention rate of antioxidants such as green tea polyphenols, while maintaining the integrity of the microcapsule structure, thus guaranteeing the product's claimed core functions such as energizing, antioxidant, anti-fatigue, and probiotic effects. The uniformity of the entire system is also improved, preventing clumping or component separation caused by localized overheating or insufficient dissolution. Standardized temperature control points and feeding sequences ensure a high degree of consistency in product quality across different production batches, reducing quality risks caused by operational fluctuations.

[0024] Thirdly, this application provides an instant freeze-dried coffee making device, the device including a mold forming module, a freezing module and a vacuum drying module, wherein the mold forming module is designed to form freeze-dried coffee blocks in mini cubes, flakes or other customized shapes; The mold forming module includes a vibration device for removing air bubbles during the pouring process to ensure a uniform product structure. The mold forming module is made of food-grade silicone or metal material, and the mold cavity depth is 2-10mm, which is suitable for rapid demolding and oral dissolution.

[0025] Through the above technical solutions, the device realizes integrated production from raw material dissolution, mold forming, low-temperature pre-freezing to vacuum drying, meeting the needs of rapid prototyping, customizable shapes, and oral dissolution. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 A flowchart illustrating a process for making ready-to-eat freeze-dried coffee, as provided in one embodiment of this application. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0029] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article, unless otherwise specified, generally indicates that the preceding and following related objects have an "or" relationship.

[0030] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0031] Conventional freeze-dried coffee products are brittle and fragile, making them inconvenient to carry and use. Furthermore, their relatively simple formulations make it difficult to effectively protect various heat-sensitive functional components while simultaneously achieving flavor synergy and texture optimization. In particular, ensuring high retention rates and stability of highly temperature- and shear-sensitive active substances such as probiotics, slow-release encapsulated compounds, and plant extracts during industrial production remains a pressing technical challenge. Therefore, developing a ready-to-eat freeze-dried coffee product that simultaneously offers excellent flavor, instant consumption, and specific functional activities is of significant practical importance.

[0032] Based on this, this application provides a process, apparatus, and the resulting freeze-dried coffee for ready-to-eat consumption. Through a low-temperature vacuum freeze-drying process, the original aroma, active ingredients (such as polyphenols and caffeine), and nutritional value of the coffee are highly preserved, avoiding degradation caused by traditional heat processing. The synergistic effect of fat powder and dietary fiber forms a uniform porous structure, enabling rapid oral solubility and ensuring the ready-to-eat nature of the freeze-dried coffee, while reducing the hygroscopicity of the freeze-dried blocks. The introduction of active ingredients expands the product's health benefits, such as energizing, antioxidant, and anti-fatigue properties, and the formulation ratio range is wide, allowing for adjustments according to market demand (such as low-sugar, high-fiber, or specific functional versions). This formulation is highly compatible with subsequent processes, ensuring batch-to-batch consistency and the feasibility of large-scale production. Specific implementation methods can be found in the following embodiments.

[0033] In some embodiments, the ready-to-eat freeze-dried coffee comprises the following ingredients by weight percentage: Coffee (1-40%): Serving as the core flavor and functional matrix, providing caffeine and natural antioxidants. Coffee raw materials can be one or more of the following: coffee extract, coffee concentrate, instant coffee powder, freeze-dried coffee powder, or ground coffee, to ensure flavor intensity and solubility. For example, using coffee extract can enhance aroma, while instant coffee powder simplifies the process.

[0034] Fat powder (3-16%): Its main function is to improve texture and reduce crystallization tendency during freeze-drying, forming fine oil particles to enhance smoothness. Fat powder can be selected from one or more of coconut oil powder, medium-chain triglyceride (MCT) powder, butter powder, or cocoa powder. For example, MCT powder provides rapid energy release, while cocoa powder adds chocolate flavor.

[0035] Dietary fiber (1-8%): Forms a network structure in the matrix, improving the mechanical strength and stability of the product and preventing freeze-dried blocks from crumbling. Dietary fiber can be selected from one or more of inulin, resistant dextrin, polydextrose, or fructooligosaccharides. These fibers also have prebiotic properties, promoting gut health.

[0036] Carbohydrates (3-12%): Used as structural fillers and sweeteners to adjust the sweetness and firmness of products. Carbohydrates can be selected from one or more of sucrose, glucose, trehalose, xylitol, or sorbitol. For example, trehalose has water-retaining and cryoprotective properties, which help stabilize the active ingredients.

[0037] At least one active ingredient: Added according to functional needs, such as sustained-release caffeine, plant antioxidants, adaptogens, or probiotics / prebiotics, to achieve effects such as energizing, antioxidant, anti-fatigue, or gut health benefits. The addition of active ingredients must consider heat sensitivity and compatibility.

[0038] Purified water: used as a solvent to dissolve and homogenize all raw materials. It is completely removed during freeze-drying by sublimation, ensuring a low moisture content (usually less than 5%) in the final product and extending its shelf life.

[0039] Beneficial effects: The low-temperature vacuum freeze-drying process highly preserves the original aroma, active ingredients (such as polyphenols and caffeine), and nutritional value of coffee, avoiding degradation caused by traditional heat processing; the synergistic effect of fat powder and dietary fiber forms a uniform porous structure, giving the product rapid oral solubility while reducing the hygroscopicity of the freeze-dried blocks; the introduction of active ingredients expands the product's health benefits, such as energizing, antioxidant, and anti-fatigue properties, and the wide range of formulation ratios allows for adjustments based on market demand (such as low-sugar, high-fiber, or specific functional versions); the formulation is highly compatible with subsequent processes, ensuring batch-to-batch consistency and the feasibility of large-scale production.

[0040] Alternative or modified implementation methods: The coffee raw material can be instant coffee powder, coffee concentrate, coffee grounds, or freeze-dried coffee extract; the fat powder can be replaced with other vegetable oil powders or animal-derived milk powder; the dietary fiber can be other soluble or insoluble fibers such as oat beta-glucan; the carbohydrates can be different combinations of oligosaccharides or sweeteners; fruit or nut flavorings can be added according to taste requirements; the types and contents of active ingredients can be increased or decreased according to functional requirements.

[0041] In some embodiments, the active ingredients include sustained-release caffeine and a plant antioxidant; the sustained-release caffeine content is 0.5-10%, and the sustained-release caffeine is encapsulated using microencapsulation technology; the plant antioxidant is green tea extract, with a content of 0.1-5%, used to construct a dual-effect matrix of energizing and antioxidant properties.

[0042] Traditional ready-to-drink coffee products contain caffeine, which is absorbed and metabolized quickly, potentially leading to rapid excitation of the nervous system and subsequent fatigue. Furthermore, caffeine is prone to degradation during high-temperature processing, affecting the stability and intensity of its energizing effect. Simultaneously, some of the antioxidants in coffee are lost during processing. This solution introduces microencapsulated slow-release caffeine and green tea extract to construct a dual-effect matrix of "energizing and antioxidant" properties. Microencapsulation technology utilizes natural wall materials to encapsulate caffeine, forming microscopic closed capsules. This not only effectively isolates caffeine from the destructive effects of heat, oxygen, and moisture during dissolution, sterilization, and freeze-drying, but also achieves slow release of caffeine by controlling the dissolution rate of the wall material in the gastrointestinal tract, thereby prolonging the duration of energizing effects and avoiding concentration spikes. The core active ingredient in green tea extract—catechins (such as epigallocatechin gallate ester EGCG)—is a potent natural antioxidant that maintains high activity even under the low-temperature environment of freeze-drying. When it works synergistically with slow-release caffeine, it can eliminate excess free radicals that may be generated during the body's metabolism and the effects of caffeine, and help maintain the redox balance of cells, thus supporting the body's energy and health from two dimensions.

[0043] In this embodiment, the active ingredient includes: Slow-release caffeine (0.5-10%): Its core lies in its microencapsulation structure. Specifically, it can be prepared via an emulsification-spray drying method: the caffeine core material is dispersed in a composite wall material solution composed of food-grade gelatin and gum arabic, homogenized under high pressure to form an oil-in-water emulsion, and then instantly dried in a spray drying tower at an inlet air temperature of 150-180℃ and an outlet air temperature of 60-80℃, forming regular spherical microcapsules with a particle size distribution of 10-50µm. This particle size range ensures good suspension in the slurry, preventing sedimentation and achieving uniform distribution in the final product. The microcapsule wall remains stable in the acidic environment of the mouth and stomach, and begins to gradually dissolve and release caffeine after entering the neutral environment of the intestine.

[0044] Plant antioxidants (0.1-5%): Specifically, standardized green tea extract powder, requiring a total catechin content of not less than 60%, of which EGCG content is not less than 30%. This extract is added in the later stages of the formulation in the form of dry powder. Its function is to act as a highly efficient antioxidant unit, directly neutralizing free radicals, and complementing and enhancing the physiological effects of sustained-release caffeine.

[0045] Beneficial effects: Microencapsulation significantly improves the retention rate of caffeine during processing and achieves sustained-release properties in the body for 4-6 hours, providing a smooth and lasting energizing experience and avoiding discomfort such as rapid heartbeat; Green tea extract retains high antioxidant activity after freeze-drying, providing consumers with clear health benefits and helping to combat daily oxidative stress; "slow-release energizing" and "sustained antioxidant" complement each other functionally, working together to improve the body's energy levels and health status, forming a product competitiveness of 1+1>2; The microcapsule structure effectively masks the bitterness of caffeine and protects green tea polyphenols from oxidative browning, improving the product's sensory attributes and shelf-life appearance.

[0046] Alternative or modified implementation methods: The microcapsule wall material can be replaced with chitosan, polylactic acid, or other food-grade edible polymers; the particle size of the sustained-release caffeine can be adjusted to different ranges by adjusting the spray parameters; the green tea extract can be replaced with other sources rich in catechins, such as grape seed extract or white tea extract, with the content range adjusted accordingly.

[0047] In some embodiments, the active ingredient includes an adaptogen, namely Rhodiola Rosea extract, at a content of 0.1-3%, for anti-stress and anti-fatigue functions.

[0048] In today's fast-paced life, physical and mental stress often leads to fatigue, poor concentration, and cognitive decline. Traditional stimulants (such as high-dose caffeine) may provide a temporary boost to alertness, but they often only treat the symptoms, not the root cause, and may even exacerbate anxiety and energy depletion. This implementation plan introduces an adaptogen—Rhodiola Rosea extract—aimed at fundamentally enhancing the body's resistance and adaptability to non-specific stress. The mechanism of action of adaptogens lies in their ability to bidirectionally regulate the activity of the hypothalamus-pituitary-adrenal axis (HPA axis) and help the body restore homeostasis by influencing neurotransmitter levels (such as serotonin and dopamine) and energy metabolism (such as increasing ATP synthesis). Key active substances in Rhodiola Rosea, such as rhodioloside and tyrosol, have been shown to reduce excessive secretion of the stress hormone cortisol, improve mood, and enhance physical and mental endurance. In the low-temperature processing system of freeze-dried coffee, these phenylpropanoids and terpenoids remain highly stable, ensuring that they perform their intended physiological functions in the final product. In synergy with the sustained-release caffeine and green tea extract in claim 2, this solution constructs a multi-dimensional functional network ranging from "instant energization" to "sustained stress relief" and "long-term antioxidant effects."

[0049] In this embodiment, the active ingredient further includes: The adaptogenic ingredient is specifically a standardized Rhodiola Rosea root extract at a concentration of 0.1-3%. To ensure consistency and traceability of efficacy, the extract should be standardized for its signature components, typically requiring a total content of at least 3% for rhodioloside and tyrosol.

[0050] Morphology and Integration: The extract is added in the form of a finely dried powder with a particle size controlled within the range of 50-200 µm. This particle size selection is based on two considerations: firstly, to ensure sufficient suspension in the slurry, avoiding sedimentation before pouring and ensuring uniform distribution in the product; and secondly, to ensure bioavailability after rapid dissolution in the oral cavity.

[0051] Synergistic Functions: Rhodiola Rosea extract is not used in isolation within the formulation; it works in conjunction with microencapsulated sustained-release caffeine and green tea extract to form a comprehensive "energy and stress-relief matrix." Suppressed-release caffeine provides an immediate boost to alertness, while Rhodiola Rosea regulates stress responses and delays the onset of fatigue in the medium to long term, and green tea extract eliminates oxidative stress products generated throughout the process. The three complement and enhance each other's functions.

[0052] Beneficial effects: The product transcends its mere function of stimulating the nervous system, transforming into a functional food that helps users manage daily stress, enhance overall endurance, and improve mental resilience. Slow-release caffeine (acting on adenosine receptors), Rhodiola Rosea (regulating the HPA axis and neurotransmitters), and green tea extract (antioxidant) work synergistically through different physiological pathways, achieving a synergistic effect greater than the sum of its parts (1+1+1>3). The user experience shifts from simply "unconscious to alert" to a holistic improvement in well-being, moving from fatigue and stress to abundant energy. The introduction of scientifically backed and in-demand adaptogens significantly enhances the product's technological content and market competitiveness, meeting the needs of specific groups such as those engaged in high-intensity mental work and students. Thanks to the low-temperature characteristics of the freeze-drying process, heat-sensitive bioactive components in Rhodiola Rosea are efficiently preserved, ensuring the product's intended functions.

[0053] Alternative or modified implementation methods: The adaptogen can be replaced with other proven adaptogen plant extracts, such as Acanthopanax senticosus, Astragalus membranaceus, or Lycium barbarum extracts; the extraction method can be water extraction, alcohol extraction, or ultrasound-assisted extraction; and the drying form can be powder or microcapsules.

[0054] In some embodiments, the active ingredient further comprises probiotics or prebiotics, wherein the probiotics are Lactobacillus or Bifidobacterium, and the content is 10. 6 -10 9 CFU / g, wherein the prebiotic is fructooligosaccharide or inulin derivative, and its content is 1-5%.

[0055] Gut health directly impacts immunity, nutrient absorption, and even mood. In today's fast-paced and stressful world, maintaining a balanced gut microbiota is crucial. This solution introduces probiotics and prebiotics into ready-to-eat freeze-dried coffee to directly supplement beneficial bacteria and provide them with specific nutrients, thereby synergistically improving the gut microbiota. However, integrating live probiotics into food presents significant challenges: high temperatures, moisture, oxygen, and the highly acidic environment of the stomach can all lead to substantial bacterial inactivation. This solution addresses these challenges through the following strategies: First, it selects freeze-dried probiotic strains with good acid and bile salt tolerance and adds them in a dormant freeze-dried powder form; second, it utilizes the characteristics of vacuum freeze-drying technology—rapid deep freezing induces dormancy in the bacteria, followed by sublimation of water under vacuum, all within a low-temperature, low-oxygen environment, minimizing heat and oxidative damage; finally, it simultaneously adds prebiotics to the formula. As indigestible dietary fiber, these prebiotics selectively stimulate the proliferation and activity of probiotics in the gut, creating a synergistic "bacteria + food" effect. This "synbiotic" design concept ensures that a sufficient amount of live bacteria can reach the intestines, colonize, and exert their effects.

[0056] In this embodiment, the active ingredient further includes: Probiotics: The specific strains are Lactobacillus and / or Bifidobacterium, and the amount added is ensured to reach 10% in the final product. 6 -10 9 The viable count is measured in CFU / g. For example, clinically validated strains such as *Lactobacillus paracasei*, *Lactobacillus rhamnosus*, or *Bifidobacterium animalis* can be used. These strains are available in commercially available, freeze-dried bacterial powder form from third parties, and the viable count is typically higher than 80%.

[0057] Prebiotics: Specifically, fructooligosaccharides and / or inulin derivatives, with a content of 1-5%. It is worth noting that the prebiotic components here can partially or completely overlap with the dietary fiber (such as inulin) used as a structural component in the aforementioned embodiments, achieving "multiple uses of one material," both constructing the product structure and serving as a substrate for probiotics.

[0058] Addition process: The probiotic powder is set to be added at the last stage of the dissolution and sterilization step (S1), when the material has cooled to below 30°C, and is evenly dispersed by gentle stirring (e.g., 200-400 rpm) to avoid the fatal impact of high-temperature sterilization on the bacterial population.

[0059] Protection strategy: Prebiotics are added together with other dietary fibers in the early stages of dissolution. The porous structure formed after freeze-drying not only provides a framework for the product, but also provides a physical shelter for probiotics, which helps to mitigate the damage of environmental factors to the bacteria during storage.

[0060] Beneficial effects: The product has been upgraded from a simple energy booster to a functional food that also supports gastrointestinal health, satisfying consumers' pursuit of "inside and out" health. Thanks to precise additive processes and freeze-drying protection, the number of live bacteria in the product remains stable within the promised range at the time of manufacture. Furthermore, through in vitro simulated gastrointestinal fluid testing, a significant proportion of the strains have been verified to be resistant to gastric acid and bile salts, successfully reaching the intestines. The presence of prebiotics significantly improves the survival rate and colonization ability of exogenously supplemented probiotics, enabling them to establish a dominant flora in the intestines more quickly, inhibiting harmful bacteria, and thus more effectively regulating the balance of intestinal flora. While retaining the energy-boosting, stress-relieving, and antioxidant functions of coffee, the added dimension of intestinal health greatly broadens the product's target audience and market appeal, making it especially suitable for consumers who are concerned about digestive health and immunity.

[0061] Alternative or modified implementation methods: Probiotic strains can be replaced with other low-temperature resistant lactic acid bacteria or bifidobacterium strains, such as Lactobacillus plantarum and Bifidobacterium longum; prebiotics can be replaced with galactooligosaccharides, xylose oligosaccharides, or other derivatives of inulin, with the content adjusted accordingly.

[0062] In some embodiments, the coffee ingredient may be selected from one or more of coffee extract, coffee concentrate, instant coffee powder, freeze-dried coffee powder, or ground coffee powder; the fat powder may be selected from one or more of coconut oil powder, medium-chain triglyceride powder, butter powder, or cocoa powder; the dietary fiber may be selected from one or more of inulin, resistant dextrin, polydextrose, or fructooligosaccharides; and the carbohydrate may be selected from one or more of sucrose, glucose, trehalose, xylitol, or sorbitol.

[0063] Integrating multiple functional ingredients (such as slow-release caffeine, plant extracts, and adaptogens) into ready-to-drink freeze-dried coffee often presents significant sensory challenges. These active substances, especially plant extracts and adaptogens, often have a pronounced inherent bitterness, metallic taste, or herbal flavor, which can severely mask the pleasant flavor of coffee itself, leading to reduced consumer acceptance. Meanwhile, the traditional method of using sucrose or artificial sweeteners / flavorings to improve flavor no longer meets modern consumers' demands for "clean labels" and natural health benefits. This implementation plan aims to address this core contradiction by constructing a "natural flavor modification system." Its working principle is as follows: using high-intensity natural sweeteners (such as steviol glycosides and mogrosides) to directly counteract and mask the bitterness perceived by bitter taste receptors (such as the TAS2R family); simultaneously, introducing synergistic natural flavor substances (such as vanillin and theobromine), which not only provide pleasant aromas but also further neutralize or divert attention from unpleasant flavors through interaction with taste buds and olfactory receptors, enhancing the body and smoothness of the coffee. The low-temperature characteristics of vacuum freeze-drying process can preserve the volatile aroma components of these natural flavor substances to the maximum extent, avoiding their loss in traditional high-temperature processing, and ensuring that the product can quickly release a full and natural aroma after rehydration.

[0064] In this embodiment, the composition further comprises: Natural sweeteners: selected from steviol glycosides, mogrosides, and mixtures thereof, with a content of 0.01%-0.5% in the composition. This extremely low dosage range stems from their high sweetness characteristics (steviosides are approximately 200-300 times sweeter than sucrose, and mogrosides are approximately 150-200 times sweeter). In practical applications, the two are often used in a certain ratio (e.g., 1:1 to 1:2) to mask the potential bitterness or licorice-like aftertaste that the other may impart, thereby obtaining a pure sweetness closer to sucrose.

[0065] Natural flavoring substances: selected from vanilla bean extract, natural cocoa powder and mixtures thereof, and their content in the composition is 0.5%-5%.

[0066] Vanilla bean extract: Its core flavor component, vanillin, not only provides a classic creamy sweetness, but has also been shown to act as a "flavor enhancer," rounding out the overall flavor profile and reducing sensory roughness.

[0067] Natural cocoa powder: Its rich theobromine and various flavor compounds can give the product a rich chocolate and nutty aroma, and can complement the roasted flavor of coffee perfectly, together creating a more complex and sophisticated flavor profile.

[0068] Beneficial effects: It effectively masks the unpleasant flavors introduced by various functional ingredients, transforming the product from a "functional medicine" to a "delicious and enjoyable food," greatly enhancing consumers' eating pleasure; it uses all natural plant-derived ingredients, aligning with the trend of clean labeling; the freeze-drying process "freezes" the flavor, allowing heat-sensitive natural aroma substances to be fully preserved; when the product is rehydrated, the porous structure of the freeze-dried block promotes the rapid and uniform release of flavor substances, achieving an "instant aroma" effect.

[0069] Alternative or modified implementation methods: coffee base can be used in single or compound form; fat powder can be added to other vegetable oil powders such as soybean oil powder; dietary fiber can be added to oat beta-glucan or apple fiber; carbohydrates can be added to erythritol or mannitol according to sweetness requirements.

[0070] Figure 1 A flowchart illustrating a process for making ready-to-eat freeze-dried coffee, as provided in one embodiment of this application. Figure 1 As shown, the process includes: S1. Dissolving and sterilizing: Dissolve all raw materials in water at 65-75℃ by stirring for 10-20 minutes, then emulsify by shearing at 3000-10000 rpm for 10-20 minutes, add water to make up the volume, sterilize, and cool to room temperature to obtain a liquid sample. S2, Mold casting: The liquid sample is injected into the mold, the air bubbles are expelled by the vibration of the equipment, and the surface of the mold is smoothed by a scraper after casting. S3. Pre-freezing and demolding: Keep the material frozen in an environment of -20℃ to -45℃ for 5 to 12 hours. After the material is kept at the set temperature for 1 to 3 hours, separate the material from the mold. S4. Secondary pre-freezing: Place the demolded material in a freezer for freezing, maintaining the freezing temperature at -45℃ to -80℃ for 1-3 hours; S5. Vacuum drying: After pre-freezing is completed, start the vacuum pump and begin vacuum drying, maintaining the drying process for 20-60 hours.

[0071] S6. Unloading and Packaging: After vacuum drying is completed, the material is taken out and sealed in high-barrier individual packaging.

[0072] The functional components (such as probiotics and antioxidants) and sensory qualities (such as aroma and flavor) of multifunctional ready-to-eat freeze-dried coffee are highly susceptible to environmental factors, particularly moisture, oxygen, and physical shock. While traditional powdered freeze-dried products rehydrate quickly, they suffer from problems such as easy moisture absorption and clumping, uneven component distribution, and dust generation and loss during transportation and use. This implementation plan aims to systematically address these challenges by designing a well-defined freeze-dried block with specific structural strength, combined with a high-barrier, independent packaging system. Its core working principle is to precisely control the solids content, viscosity, and freezing process of the slurry to form a microstructure with a highly interconnected porous network and sufficient mechanical strength. This structure ensures that the freeze-dried block can withstand the normal vibrations and compression during packaging and transportation while maintaining its shape, and its large specific surface area allows for rapid dissolution in the mouth, ensuring its ready-to-eat nature. Furthermore, each freeze-dried block is individually packaged and high-barrier materials and atmosphere conditioning technology are used to provide a long-term stable "microenvironment" for this sophisticated structure and its internal functional matrix, thereby maximizing the protection of the product's physical integrity, functional activity and flavor freshness during its shelf life.

[0073] Through the above manufacturing process, the density of the freeze-dried block is controlled within the range of 0.2-0.5 g / cm³. This density range represents the optimal balance between rapid rehydration and maintaining structural strength. Too low a density results in brittleness, while too high a density leads to slow dissolution. The porosity of the freeze-dried block is between 70% and 90%. This high porosity ensures that moisture can rapidly penetrate the entire interior of the freeze-dried block through capillary action. The freeze-dried block, with its specific physical structure, serves as a carrier for all functional ingredients (coffee, slow-release carriers, plant extracts, probiotics, etc.) and sensory components (flavor compounds, sweeteners), and its uniformity guarantees consistent dosage in every product serving.

[0074] Each of the aforementioned ready-to-eat freeze-dried blocks is packaged in an individual packaging unit. This individual packaging can be in the form of a small pouch or a specially shaped blister pack. The individual packaging is made of a high-barrier composite material, preferably an aluminum-plastic composite film or a high-barrier aluminized plastic film. Its key performance parameters must meet the following requirements: oxygen permeability <0.5 cm³ / (m²·day·atm) and water vapor permeability <0.5 g / (m²·day). During the packaging process, the interior of the individual packaging is nitrogen-filled or vacuum-sealed to reduce the headspace oxygen content inside the packaging to below 3%. This aims to create an inert environment, effectively preventing flavor degradation and functional ingredient deactivation caused by oxidation.

[0075] Beneficial effects: Freeze-dried blocks with specific density and porosity possess optimal structural strength, effectively resisting impacts and pressures during transportation, ensuring the product arrives intact to consumers. The combination of high-barrier packaging materials and nitrogen-filled / vacuum technology creates a robust barrier, effectively blocking moisture, oxygen, and light, providing full-cycle protection for core functional ingredients (such as probiotic activity and the stability of the slow-release system) and coffee flavor from manufacturing to consumption. Individual packaging ensures hygiene, precision, and convenience for each consumption. The regular shape of freeze-dried blocks offers superior visual appeal compared to powders, while their rapid rehydration properties provide a seamless mixing experience. The freeze-drying process ensures that various components in the slurry are "locked" within the microstructure of the freeze-dried blocks, avoiding the component separation problems that may occur with powdered products, and ensuring the consistency of efficacy and flavor in every serving.

[0076] Alternative or modified implementation methods: The temperature range in S1 can be adjusted to 60-80℃; the shearing speed can be set to 2000-12000rpm; the mold material can be replaced with food-grade metal or polymer; the pre-freezing temperature can be in the low-temperature range of -10℃ to -30℃; the vacuum degree can be adjusted within the range of 0.05-2Pa; the packaging form can be a vacuum bag, aluminum foil box, or resealable plastic container.

[0077] In some embodiments, the retention rate of active ingredients is optimized by controlling the pre-freezing rate at 1-5 °C / min and the vacuum degree at 0.1-1 Pa during the vacuum drying step.

[0078] The core of vacuum freeze-drying (lyophilization) lies in removing moisture through low-temperature pre-freezing and vacuum sublimation. However, the pre-freezing rate and vacuum level significantly affect the retention of active ingredients. The pre-freezing rate directly determines the nucleation and growth behavior of ice crystals: a slower pre-freezing rate (e.g., 1-5 °C / min) promotes the formation of larger and more uniform ice crystals, thereby reducing mechanical stress on the microstructure of the material during sublimation and avoiding cell wall rupture or physical damage to active molecules (such as polyphenols and probiotic cells). Simultaneously, the vacuum level controls the sublimation rate and heat transfer: a lower vacuum level (e.g., 0.1-1 Pa) lowers the sublimation point of water (approximately -30 °C to -40 °C), reducing heat input and preventing the decomposition of heat-sensitive components (such as microcapsule wall materials or antioxidants) due to localized heating. Studies have shown that excessively fast pre-freezing rates (>5 °C / min) may result in small and irregular ice crystals, increasing sublimation resistance and triggering component migration; while excessively high vacuum levels (<0.1 Pa), although accelerating sublimation, may introduce the risk of overcooling, causing inactivation of active ingredients. Therefore, this embodiment maximizes the stability of active ingredients while ensuring drying efficiency by balancing pre-freezing and vacuum parameters.

[0079] A precise cooling profile is achieved using a programmable temperature control system (such as a PLC-controlled liquid nitrogen or ethylene glycol cooling system). The system cools from room temperature to the target pre-freezing temperature (-45°C to -80°C) at a rate of 1-5°C / min, and monitors the internal temperature of the material in real time using a high-precision temperature sensor (such as the PT100 type), feeding back the data to the control unit to adjust the cooling power. For example, a slower rate (1-2°C / min) is used in the initial pre-freezing stage (0°C to -10°C) to promote uniform ice crystal nucleation, while the rate can be appropriately increased (3-5°C / min) in the later stage (below -10°C) to shorten the total time.

[0080] During the vacuum drying stage, a two-stage vacuum system (including a coarse vacuum pump and a molecular pump) is used to maintain a stable pressure of 0.1-1 Pa. The vacuum pump (such as a rotary vane pump or dry pump) is linked to a pressure regulating valve, and a PID controller dynamically adjusts the pumping rate based on pressure sensor data to avoid sublimation instability caused by pressure fluctuations. Simultaneously, the system integrates a cold trap (temperature ≤ -50℃) to capture water vapor and prevent it from returning to the material surface. To verify the retention rate, samples can be taken during the drying process to detect key components (e.g., caffeine content analyzed by HPLC, and probiotic survival rate measured by plate counting).

[0081] Beneficial effects: By limiting the pre-freezing rate and vacuum level in the vacuum drying step, thermal degradation and physical damage are significantly reduced, allowing functional ingredients (such as sustained-release caffeine, green tea antioxidants, and adaptogen extracts) to maintain high retention rates in the final product.

[0082] In some embodiments, during the mold casting step, the mold is designed as a mini cubic or sheet shape, and the shape and texture of the freeze-dried coffee are controlled by adjusting the slurry viscosity to 100-500 cP.

[0083] The final form and texture of the product are key quality attributes of ready-to-eat freeze-dried coffee. The geometry of the mold (such as mini cubes or flakes) directly determines the unit size, surface area, and volume ratio of the product, thus affecting the mass and heat transfer efficiency during freeze-drying, as well as the convenience and dissolution speed for consumers. Flake-shaped products have a larger specific surface area, which facilitates rapid water sublimation, shortens drying time, and achieves instant dissolution in the mouth; while mini cubes can provide a more substantial chewy texture or a longer-lasting dissolution experience.

[0084] Slurry viscosity is a core physical parameter for controlling the quality of casting. Too low a viscosity (<100 cP) will cause the slurry to flow excessively in the mold, making it difficult to maintain the intended shape, and solids are prone to settling, resulting in uneven component distribution. Too high a viscosity (>500 cP) will reduce the slurry's fluidity, making it difficult for internal air bubbles to be effectively expelled through vibration, easily causing defects during casting, and the freeze-dried product may be too hard, affecting its taste. Controlling the viscosity within the ideal range of 100-500 cP ensures that the slurry has sufficient viscosity to maintain its shape, while also possessing good fluidity for easy casting, leveling, and degassing, ultimately forming an ideal freeze-dried structure with uniform structure and appropriate porosity.

[0085] The molds are precision-machined into miniature cubes (e.g., 5mm × 5mm × 5mm) or sheet shapes (e.g., 20mm × 20mm × 3mm). This small size and specific shape design aims to achieve rapid freeze-drying and a melt-in-your-mouth experience. The mold body is made of food-grade silicone or stainless steel (e.g., 304 / 316L). Silicone molds offer excellent flexibility, facilitating demolding after freezing and effectively preventing product damage; metal molds have good thermal conductivity, promoting rapid and uniform freezing. The mold cavity depth is strictly controlled between 2-10 mm to balance molding efficiency and drying rate. The molds are mounted on a vibration platform equipped with a frequency converter. After the slurry is injected, the vibration equipment is activated, performing low-frequency, high-amplitude vibration at 50-100 Hz for 10-30 seconds. This mechanical energy forces internal air bubbles to rise and burst, ensuring a dense, void-free internal structure for the product.

[0086] The viscosity of the slurry is primarily adjusted through two collaborative methods: firstly, coarse adjustment is achieved by controlling the moisture content in the formulation; secondly, fine adjustment is made by adding food-grade thickeners or stabilizers when necessary, such as 0.1%-0.5% hydroxypropyl methylcellulose (HPMC) or microcrystalline cellulose. The viscosity of the homogenized slurry is measured online or offline using a rotational viscometer (such as a Brookfield viscometer) at 25°C to ensure it remains stable within the range of 100-500 cP. An automatic viscosity feedback system can be integrated into the production line to fine-tune the water replenishment amount based on the measured values.

[0087] Beneficial effects: The homogeneous slurry formed through viscosity control produces a fine, porous structure after freeze-drying. This results in a product with satisfactory crispness, dissolves quickly in the mouth, releasing flavor and avoiding an unpleasant gritty or cloying taste. Effective degassing and viscosity control fundamentally reduce product defects (such as bubbles and cracks), significantly improving production yield.

[0088] In some embodiments, during the dissolution and sterilization step, the active ingredients are added in the following order: first, dissolve the fat powder and dietary fiber, then add the coffee and carbohydrates, and finally add the active ingredients to avoid degradation of heat-sensitive ingredients; wherein the active ingredients include slow-release caffeine, green tea extract, Rhodiola Rosea extract, probiotics or prebiotics, and the probiotics are added when cooled to below 30°C to maintain their activity.

[0089] Different raw material components exhibit significant differences in their stability under heat treatment. Improper addition sequence and temperature control are key causes of product functional failure. Fat powder and dietary fiber are the backbone components for building system stability, requiring full hydration and swelling at relatively high temperatures (65-75℃) to form a stable emulsion network structure with the help of shear forces. This lays the foundation for the uniform dispersion of subsequent components. Coffee and carbohydrates exhibit optimal solubility within this temperature range, and their flavor and sweetness components are relatively stable.

[0090] However, the core functional active ingredients are generally sensitive to high temperatures: microencapsulated sustained-release caffeine may have its wall materials (such as gelatin and HPMC) soften or rupture under sustained high temperatures, leading to premature release of caffeine; plant antioxidants (such as green tea polyphenols) and adaptogens (such as phenolic glycosides in Rhodiola Rosea) are prone to oxidation and isomerization in the presence of high temperatures and oxygen, resulting in loss of activity; and probiotics, as living microorganisms, will die off in large numbers when the temperature exceeds 40°C. Therefore, placing these ingredients at the end of the process chain and adding them at lower temperatures is a physical barrier to ensure their functionality.

[0091] The segmented feeding process is carried out in a jacketed heating and melting tank equipped with a high-shear emulsifying head (3000-10000 rpm) and multiple feeding ports. The control system is programmed to execute automatically or semi-automatically according to the following sequence: Stage 1 (High-Temperature Emulsification): Inject a measured amount of purified water at 65-75℃ and start stirring. Add fat powder and dietary fiber sequentially, and emulsify at high speed for 10-20 minutes to form a homogeneous and stable emulsion.

[0092] Phase 2 (Main Dissolution): While stirring, add coffee ingredients (such as instant coffee powder, coffee concentrate) and carbohydrates (such as sucrose, trehalose), and use the residual heat of the system to fully dissolve them. Continue running for 5-10 minutes.

[0093] Phase Three (Sterilization and Cooling): The dissolved liquid is brought to a constant volume and sterilization is performed (e.g., pasteurization at 85°C / 15s or ultra-high temperature instantaneous sterilization). Immediately afterwards, the jacketed cooling circulation system is activated to forcibly cool the liquid.

[0094] Phase 4 (Addition of heat-sensitive ingredients): When the temperature sensor shows that the liquid temperature has dropped below 40°C, add slow-release caffeine, green tea extract, Rhodiola Rosea extract and prebiotics (such as fructooligosaccharides), and gently stir for 5-10 minutes to ensure even dispersion.

[0095] Phase 5 (Probiotic Addition): When the temperature is confirmed to have dropped to 30℃ or lower, add the freeze-dried probiotic powder and gently stir for 3-5 minutes to avoid high-speed shearing damage to the bacteria. Then proceed to the next mold casting process.

[0096] Beneficial effects: This staged addition strategy can maintain the survival rate of probiotics at 10%. 8 -10 9 The high CFU / g level ensures a high retention rate of antioxidants such as green tea polyphenols, while maintaining the integrity of the microcapsule structure, thus guaranteeing the product's claimed core functions such as energizing, antioxidant, anti-fatigue, and probiotic effects. The uniformity of the entire system is also improved, preventing clumping or component separation caused by localized overheating or insufficient dissolution. Standardized temperature control points and feeding sequences ensure a high degree of consistency in product quality across different production batches, reducing quality risks caused by operational fluctuations.

[0097] In some embodiments, the ready-to-eat freeze-dried coffee making device includes a mold forming module, a freezing module, and a vacuum drying module. The mold forming module is designed to form freeze-dried coffee blocks in mini cubes, flakes, or other custom shapes. The mold forming module includes a vibration device for removing air bubbles during the pouring process to ensure a uniform product structure. The mold forming module is made of food-grade silicone or metal material, and the mold cavity depth is 2-10 mm, suitable for rapid demolding and oral dissolution.

[0098] Technical background and working principle: The material and structure of the mold forming module determine the shape retention and demolding ease of the product; the vibration equipment reduces the air bubble content inside the liquid through mechanical vibration after casting; the freezing module provides the low temperature environment required for pre-freezing and secondary pre-freezing; the vacuum drying module completes sublimation and water removal under vacuum conditions.

[0099] The mold forming module consists of a replaceable mold cavity, a vibration platform, and a scraper; the freezing module includes an adjustable pre-freezing chamber (-20℃ to -45℃) and a secondary pre-freezing chamber (-45℃ to -80℃); the vacuum drying module is equipped with a vacuum pump, a temperature controller, and a pressure display; all metal parts are made of 304 stainless steel, and the silicone parts meet food safety standards.

[0100] Beneficial effects: The device realizes integrated production from raw material dissolution, mold forming, low-temperature pre-freezing to vacuum drying, meeting the needs of rapid prototyping, customizable shapes, and oral dissolution.

[0101] Replaceable or modified implementation methods: The mold material can be replaced with food-grade polyamide or polypropylene; the vibration method can be ultrasonic vibration or pneumatic vibration; the temperature range of the freezing module can be extended to -10℃ to -60℃; the vacuum degree of vacuum drying can be adjusted to 0.05-2Pa; the depth of the mold cavity can be adjusted to 1-15mm according to product specifications.

Claims

1. A ready-to-eat freeze-dried coffee, characterized in that, By weight percentage, it includes: 1-40% coffee, 3-16% fat powder, 1-8% dietary fiber, 3-12% carbohydrates, and at least one active ingredient, with the remainder made up to 100% with purified water.

2. The ready-to-eat freeze-dried coffee according to claim 1, characterized in that, The active ingredients include sustained-release caffeine and plant antioxidants; The sustained-release caffeine content is 0.5-10%, and the sustained-release caffeine is encapsulated using microencapsulation technology; The plant antioxidant is green tea extract, with a content of 0.1-5%, used to construct a dual-effect matrix of energizing and antioxidant properties.

3. The ready-to-eat freeze-dried coffee according to claim 2, characterized in that, The active ingredient further includes an adaptogen, which is Rhodiola Rosea extract at a content of 0.1-3%, used for anti-stress and anti-fatigue functions.

4. The ready-to-eat freeze-dried coffee according to claim 3, wherein the active ingredient further comprises probiotics or prebiotics, wherein the probiotics are lactobacilli or bifidobacteria, and the content is 10. 6 -10 9 CFU / g, wherein the prebiotic is fructooligosaccharide or inulin derivative, and its content is 1-5%.

5. The method according to claim 1, characterized in that, The coffee includes one or more of the following: coffee extract, coffee concentrate, instant coffee powder, freeze-dried coffee powder, or ground coffee powder. The fat powder includes one or more of coconut oil powder, medium-chain triglyceride powder, butter powder, or cocoa powder; The dietary fiber includes one or more of inulin, resistant dextrin, polydextrose, or fructooligosaccharides; The carbohydrates include one or more of sucrose, glucose, trehalose, xylitol, or sorbitol.

6. A process for making ready-to-eat freeze-dried coffee, characterized in that, Applied to the ready-to-eat freeze-dried coffee as described in claims 1-5, characterized in that it comprises: S1. Dissolving and sterilizing: Dissolve all raw materials in water at 65-75℃ by stirring for 10-20 minutes, then emulsify by shearing at 3000-10000 rpm for 10-20 minutes, add water to make up the volume, sterilize, and cool to room temperature to obtain a liquid sample. S2, Mold casting: The liquid sample is injected into the mold, the air bubbles are expelled by the vibration of the equipment, and the surface of the mold is smoothed by a scraper after casting. S3. Pre-freezing and demolding: Keep the material frozen in an environment of -20℃ to -45℃ for 5 to 12 hours. After the material is kept at the set temperature for 1 to 3 hours, separate the material from the mold. S4. Secondary pre-freezing: Place the demolded material in a freezer for freezing, maintaining the freezing temperature at -45℃ to -80℃ for 1-3 hours; S5. Vacuum drying: After pre-freezing is completed, start the vacuum pump and begin vacuum drying, maintaining the drying process for 20-60 hours. S6. Unloading and Packaging: After vacuum drying is completed, the material is removed and sealed in packaging.

7. The process according to claim 5, characterized in that, In the vacuum drying step, the retention rate of active ingredients is optimized by controlling the pre-freezing rate and vacuum level, wherein the pre-freezing rate is 1-5℃ / min and the vacuum level is 0.1-1Pa.

8. The method according to claim 6, characterized in that, In the mold casting step, the mold is designed as a mini cubic or sheet shape, and the shape and texture of the freeze-dried coffee are controlled by adjusting the slurry viscosity to 100-500 cP.

9. The method according to claim 7, characterized in that, In the dissolution and sterilization step, the active ingredients are added in the following order: First, dissolve the fat powder and dietary fiber, then add coffee and carbohydrates, and finally add the active ingredients to avoid the degradation of heat-sensitive ingredients; The active ingredients include slow-release caffeine, green tea extract, Rhodiola Rosea extract, probiotics or prebiotics, and the probiotics are added when cooled to below 30°C to maintain their activity.

10. A ready-to-eat freeze-dried coffee making device, characterized in that, The ready-to-eat freeze-dried coffee as described in claims 1-5 includes a mold forming module, a freezing module, and a vacuum drying module, wherein the mold forming module is designed to form freeze-dried coffee blocks in mini cubic, flake, or other custom shapes; The mold forming module includes a vibration device for removing air bubbles during the pouring process to ensure a uniform product structure. The mold forming module is made of food-grade silicone or metal material, and the mold cavity depth is 2-10mm, which is suitable for rapid demolding and oral dissolution.

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