Rapid cooling of food and drinks

Abstract

To provide a system and a method for rapidly cooling foods and drinks for making frozen beverages or frozen confections.SOLUTION: There is provided a method of making a frozen beverage or a frozen confection from a pod including a food or drinks, the method including the steps of: filling the pod with a food or beverage in a liquid form through a first end, and pressurizing an upper open height of the pod with nitrogen; hermetically sealing the first end of the pod; placing the pressurized pod into a sterilization system; simultaneously heating and mixing a food or a beverage by horizontally shaking the pod so that the food or the beverage in the liquid form sloshes in the pod; inserting the pod into the machine to freeze the food or the beverage; and operating the machine to freeze the food or the beverage and stir at least some of the nitrogen into the frozen food or beverage to produce the frozen beverage or the frozen confection.SELECTED DRAWING: Figure 3A-B

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 62 / 961,495, filed on January 15, 2020. The entire content of this application is incorporated herein by reference.

[0002] The present disclosure relates to systems and methods for rapidly cooling food and beverages.

Background Art

[0003] Single - serving beverage brewing systems for quickly preparing warm beverages have been developed. Some of these brewing systems rely on disposable pods into which water is added before brewing occurs. The pods can be used to prepare warm coffee, tea, and cocoa.

[0004] Home ice cream makers can be used to make larger batches (e.g., 1.5 quarts or more) of ice cream for personal consumption. These ice cream maker appliances typically prepare the mixture by using a hand - cranked handle method or by using an electric motor that is then used to assist in stirring the ingredients within the appliance. The resulting preparation is often cooled using a pre - cooled container that is inserted into the machine. Some electric ice cream machines take 20 to 60 minutes to make a batch of ice cream and require time - consuming cleaning.

Summary of the Invention

Problems to be Solved by the Invention

[0005] This specification describes systems and methods for rapidly cooling food and beverages. Some of these systems and methods can cool food and beverages in a container inserted into a countertop or installed machine from room temperature to frozen in less than 2 minutes. For example, the techniques described herein have successfully demonstrated the ability to make soft-serve ice cream from room temperature pods in about 90 seconds. This technique has also been used to chill cocktails and other beverages, including for making frozen drinks. These systems and methods are based on a refrigeration cycle with low startup time and a pod-machine interface that is easy to use and provides very efficient heat transfer.

[0006] Some of the pods described are filled with materials on a manufacturing line and subjected to a sterilization process (e.g., retort, aseptic packaging, ultra-high temperature treatment (UHT), ultra-heat treatment, ultra-pasteurization, or high pressure processing (HPP)). HPP is a pasteurization technique that takes a product already sealed in its final package, places it inside a container, and exposes it to a high level of hydrostatic pressure (300 to 600 megapascals (MPa) (43,500 to 87,000 pounds per square inch (psi))) transmitted by water at a low temperature. The pods can be used, for example, to store materials containing dairy products at room temperature for extended periods (e.g., 9 to 12 months) following sterilization.

[0007] Ice cream is considered a low-acid food with a pH level in the range between 5.0 and 8.0. The acidity of ice cream is shown in the following table in relation to other foods. The table shows the range of pH levels along a horizontal axis extending from high-alkali-content foods on the left to high-acid-content foods on the right. Ice cream is a low-acid food within the categories of eggs and dairy products. That is, a low-acid food is a food having a finished equilibrium pH greater than 4.6 and a water activity greater than 0.85.

Table 1

Means for Solving the Problems

[0008] Figure 1 is a process diagram of one method for manufacturing ice cream. In this method, the raw materials undergo homogenization, pasteurization, crystallization, rapid freezing, packaging, and storage.

[0009] Pasteurization is a process in which food (e.g., dairy products or milk) is treated with gentle heat, usually below 100°C (212°F), to eliminate pathogenic bacteria and extend the shelf life. The process aims to destroy or inactivate organisms and enzymes that contribute to the risk of spoilage or disease, including vegetative bacteria but not bacterial spores. Pasteurization is not sterilization and may not kill bacterial spores. Pasteurization reduces the number of organisms in the food.

[0010] The shelf life of refrigerated and pasteurized dairy products is usually longer than that of milk. For example, ultra-high temperature (UHT) treated milk can last much longer, sometimes up to two to three months, while high-temperature short-time (HTST) pasteurized milk usually has a refrigerated shelf life of two to three weeks. When UHT treatment is combined with aseptic processing container technology (e.g., the retort or aseptic packaging described above), dairy products can be stored without refrigeration for much longer periods, such as nine to twelve months.

[0011] However, during UHT processing combined with retort-based aseptic processing container technology, pasteurized dairy products may caramelize and turn brown, which may not be desirable. More generally, the maximum rate of browning, also known as the Maillard reaction, which is called the color development phenomenon, may be caused by the presence of fructose that begins to caramelize at a temperature of 230°F. Caramelization should not be confused with the Maillard reaction in which reducing sugars react with amino acids. The process of browning, i.e., the Maillard reaction, produces flavor and changes the color of the food. The Maillard reaction generally begins to occur at temperatures above 285°F. For example, the caramelization temperature of fructose may be 230°F, galactose may be 320°F, glucose may be 320°F, lactose may be 397°F, and sucrose may be 320°F.

[0012] The pasteurization process extends the shelf life, but homogenization may be required in some cases. Homogenization is usually carried out either before or after pasteurization, but before freezing of the liquid ice cream mix. Homogenization is generally carried out on any ice cream mix containing fat or oil and has conventionally been used in the production of dairy products such as milk, yogurt, ice cream, and beverages such as juice, soy milk, and peanut milk. Homogenization not only creates a uniform mix, but also reduces the size of the fat droplets, thereby stabilizing the emulsion. Homogenization leads to a higher viscosity and the production of a more uniform color. Homogenization gives ice cream its creamy texture by breaking up large fat globules.

[0013] The homogenization process occurs in a homogenizer that acts like a piston pump by drawing in air and then forcing the air out under very high pressure. This pressure is used to force the liquid ice cream through a very small tubular opening, creating very fine fat particles that prevent cream separation. The pressure depends on the fat and solids in the liquid ice cream mix. When the liquid ice cream mix contains high fat and total solids, a lower pressure may be used. When a two-stage homogenizer is used, pressures of 2000 - 2500 psi for the first stage and 500 - 1000 psi for the second stage are satisfactory under most conditions, but for low-fat ice cream, the pressure may be higher (e.g., 2,900 psi). Two-stage homogenization is preferred for ice cream mixes. Fat aggregation or clustering is reduced by producing a thinner and more rapidly whipped ice cream mix.

[0014] The high pressure of the homogenization process results in a more stable emulsion and smaller fat particles. The smaller the fat particles, the more surface area is obtained. As a result, more fat networks are created that stabilize more air, which in turn slows down ice recrystallization. In the case of high-fat ice cream, the homogenization pressure is lower. In particular, for ice cream mixes with more than 13% fat, it is preferable to reduce the pressure to minimize the risk of cluster formation. Furthermore, this process effectively mixes all materials, avoids the splitting of any soft materials, and prevents the growth of harmful bacteria. Homogenization is important in the ice cream production process because it determines the reaction of the ice cream mix when it is frozen, hardened, and dispersed. The homogenization of the ice cream mix gives the ice cream a smoother texture, a wonderful distinct richness and deliciousness, good air stability, and enhanced melt resistance.

[0015] Low-acid foods packaged in sealed containers are defined as low-acid canned foods ("LACF") and are regulated by Title 21 of the Code of Federal Regulations (21 CFR) Part 113. The sealed container is a container designed and intended to be safe against the entry of microorganisms and thereby maintain the commercial sterility of its contents after processing. Low-acid canned foods are defined by the fact that they are (i) shelf-stable at ambient temperature, (ii) heat-treated, (iii) have a pH > 4.6, and (iv) have a water activity of 0.85.

[0016] Once packaged, low-acid canned foods are sterilized. The method of sterilization is a heat-based process, i.e., applying high heat to the product. The high temperatures required in the sterilization process destroy any pathogens that may be present in or on the container and / or food product and well exceed the boiling point of water at standard atmospheric pressure. Sterilization kills or inactivates living organisms in the food product. The heat treatment / sterilization of shelf-stable low-acid foods is typically carried out at a temperature of about 250°F or above 250°F. The higher the temperature, the shorter the time the product needs to be exposed to the heat.

[0017] There are two main methods for sterilizing low-acid canned foods such as ice cream. The first method is the retort process, which is also sometimes called an autoclave or sterilizer, a pressure vessel used in the food manufacturing industry to sterilize or "commercially sterilize" the food after it has been placed in a container and the container has been sealed. The retort process or "retort" machine may be an electrostatic machine or an agitated machine. Agitated retort machines are typically used for convective (e.g., "flowable liquid") type products such as liquid ice cream that benefit from some movement of the product within the container during the process (e.g., "turbulent agitation"). These benefits may be either from a process perspective (e.g., to improve the heat transfer rate into / out of the container) and / or from a product quality perspective (e.g., to reduce the exposure time to heat). Agitated retorts can utilize various agitation methods depending on the orientation of the product container. Vertically elongated containers such as cans are usually rotated for agitation either along the axis or by rolling forward, although horizontal agitation can also be used.

[0018] The second process for sterilizing low-acid canned foods is aseptic processing, a processing technique in which a commercially heat-sterilized liquid product (usually a food such as liquid ice cream) is packaged into a previously sterilized container in a sterile state to produce a product that can be stored at room temperature without the need for refrigeration. Aseptic processing involves aseptic sealing in a microbe-free atmosphere. The regulations of 21 CFR 113 include guidance regarding the number and temperature of the sterilization process.

[0019] The best ice cream has a smooth and creamy texture. Also, this creamy texture, which is mainly associated with a high fat content, is also determined by the average size of the ice crystals. The size of the ice crystals depends not only on factors related to the freezing process, residence time, evaporation temperature of the refrigerant fluid, speed of the whisk, and extraction temperature, but also on the method of making the mix. Each of these factors is explained in detail below. Although described in relation to ice cream, the relationship between ice crystals and smoothness is also relevant to other frozen foods and beverages.

[0020] Figure 2A shows a typical relationship between smoothness and the size of ice crystals. In Figure 2A, the size of the ice crystals increases from left to right along the horizontal axis, while smoothness increases from bottom to top along the vertical axis. The typical values are shown by a generally linear trend line passing through the data. The data and trend indicate that a decreasing size of the ice crystals (down to micrometer size) is directly correlated with an increase in the smoothness of the ice cream. The size of the ice crystals can be measured by various methods such as using an optical microscope. Usually, a quantity of ice cream is analyzed and the average size of the ice crystals is measured with an optical microscope. It is expected that the ice crystal sizes have a variation. A smooth and creamy ice cream requires that most of the ice crystals are small, i.e., less than 50 μm in size, preferably in the range of 10 - 20 μm in size. If many of the crystals are larger than this, the ice cream is recognized as being coarse or icy.

[0021] The ice crystals in ice cream range in size from about 1 to over 150 μm in diameter, and the average size is about 25 μm. For example, larger ice crystals, such as those larger than 50 μm, give a granular texture, while small ice crystals in the range of about 10 - 20 μm in size give the ice cream its smooth and creamy texture.

[0022] The growth of ice crystals can be controlled using stabilizers. Stabilizers are typically used to increase the melt resistance of ice cream and extend its shelf life. Examples of stabilizers are guar gum, locust bean gum, and cellulose gum, which limit ice crystal growth by restricting the mobility of water in the unfrozen ice cream mix. Stabilizers also limit ice crystal growth by reducing the ripening that occurs during the early stages of hardening and during the storage and distribution of the ice cream mix (e.g., when the ice cream mix is exposed to relatively high temperatures (e.g., +10 to +18°F)). In these temperature ranges, the degree of freeze concentration is low, resulting in a relatively low viscosity in the unfrozen portion. The low viscosity allows water to migrate from small ice crystals to large ice crystals, which increases the average size of the ice crystals in the ice cream. Stabilizers act to limit this ice crystal growth by increasing the viscosity of the ice cream mix. Stabilizers limit the mobility of water by reducing the ripening effect during freeze concentration. Stabilizers limit the size of air bubbles that grow through an unbalanced process.

[0023] The rheological effects of stabilizers are important in stabilizing the properties of the finished ice cream with respect to the movement of water in the unfrozen system. For example, high-viscosity ice cream restricts the temperature at which the ice cream can be drawn from the barrel of an ice cream freezer and handled. When this occurs, the amount of frozen water in the freezer decreases. This has an undesirable effect on the ice cream's resistance to thermal shock. Low-viscosity stabilizers have not been used in conventional ice cream because they are assumed not to affect water mobility.

[0024] At a point called the "branch point," the degree of concentration can sometimes irreversibly interact with stabilizers and possibly other water-soluble compounds, thus significantly increasing the effect on water mobility. This can occur at low frozen storage temperatures and can be combined with extreme freeze concentration that results in other interactions between individual water-soluble compounds.

[0025] In addition to stabilizers, emulsifiers are also conventionally added to ice cream mixes. Emulsifiers migrate to the interface between the fat and water in the ice cream mix. Emulsifiers attach themselves to the surface of the fat globules and displace the protein molecules. Emulsifiers are used to improve the melting physical properties during shipping and storage. Examples of emulsifiers are monoglycerides (E471), lactate esters (E472b), propylene glycol esters (E477), and mixtures thereof.

[0026] Emulsifiers are used in ice cream because they contribute to a smooth and creamy texture by promoting the destabilization of the fat. The destabilization of the fat refers to the clustering and aggregation (known as partial coalescence) of the fat in the ice cream mix when the ice cream mix is churned in a machine. Since it is the protein that stabilizes the fat emulsifiers in the ice cream mix, emulsifiers are added to ice cream to reduce this emulsifier stability and to act to cause some of the fat globules to cluster or partially coalesce. When the mix is churned in an ice cream machine, the air bubbles incorporated while churning in the mix are stabilized by the partially coalesced fat, giving the ice cream a smooth texture. Conventionally, without the addition of emulsifiers, the air bubbles would not be properly stabilized and the ice cream would not have the same smooth texture.

[0027] Egg yolks are used both as stabilizers that give the mixture body and as emulsifiers that act to cause partial coalescence. To utilize the emulsifying properties of egg yolks, about 0.5 to 1% of the mixture needs to be egg yolk. To also utilize the stabilizing (body-giving) properties, the proportion of egg yolk is conventionally increased to 3 - 4%. However, some frozen custard style ice creams may contain more than 8% egg yolk.

[0028] Egg yolks contain lecithin, which helps make egg yolks excellent emulsifiers. In fact, egg lecithin has emulsifying and lubricant properties and is a surfactant. However, lecithin does not necessarily have to be extracted only from egg yolks. Lecithin can be extracted from plant sources such as soybeans, sunflowers, and rapeseeds, for example. Plant-based lecithin can emulsify just as well as egg yolks, without the flavor and extra fat of eggs.

[0029] Many ice creams purchased in stores contain stabilizers and emulsifiers to help prevent ice crystals from growing by improving melting properties during shipping and storage and by extending the shelf life of the ice cream. One example is Ben&Jerry's Cinnamon Buns ice cream, which contains cream, skim milk, water, sugar solution, granulated sugar, dried cane syrup, wheat flour, corn syrup, egg yolk, brown sugar, soybean oil, butter, coconut oil, sugar solution, salt, cinnamon, soy lecithin, baking soda, spices, vanilla extract, guar gum, and carrageenan. In this example, the stabilizer contains guar gum, and the emulsifiers contain egg yolk, soybean oil, soy lecithin, and carrageenan.

[0030] As described above, ice crystal size is a factor in the development of smooth and creamy ice cream. Creamy ice cream requires that most of the ice crystals be small, preferably less than 50 μm in size. If many of the crystals are larger than this, the ice cream is recognized as being coarse.

[0031] Ice cream is frozen in two stages, namely dynamic freezing and static freezing. Dynamic freezing is a dynamic process in which the mix is frozen in an ice cream machine while being stirred to incorporate air, destabilize fat, and form ice crystals. The ice cream mix enters the ice cream machine at a temperature slightly above its freezing point, i.e., the temperature at which the water in the mix begins to freeze. The ice cream machine cools the mix and brings the mix below its freezing point. At this point, a layer of ice freezes on the walls of the ice cream machine, which causes rapid nucleation where small ice crystals begin to form. Ice cream exits the ice cream machine at approximately -5°C to -6°C (23 to 21.2°F) and in a consistency similar to soft serve.

[0032] Ice cream then undergoes static freezing, where it hardens in a freezer without stirring until the center of the ice cream reaches a specified temperature, usually -18°C (-0.4°F). New ice crystals form during static freezing, but existing small crystals begin to grow in size until the temperature drops to -18°C (0.4°F), or ideally -25°C to -30°C (-9.4°F to -20.2°F), which interrupts this growth. It is advantageous to cool the ice cream as quickly as possible during this process to limit the growth of ice crystals.

[0033] During static freezing, the ice crystals typically grow by about 30% to 40% to an average size of about 25 to 45 μm. An average ice crystal size of about 50 μm is considered the average point at which consumers begin to notice a coarse texture. During static freezing, the ice crystals can often grow beyond 100 μm. Figure 2B shows an image of typical ice crystals during this process. The ice crystals in the image of Figure 2B are of various shapes and sizes, but some ice crystals have a diameter exceeding 100 μm.

[0034] However, the ice cream described in this specification does not require static freezing because the ice cream is not stored. The ice cream is supplied in a state where it can be consumed at any time. By eliminating the static freezing step, the growth of ice crystals during the static freezing process (for example, ice crystals usually grow by about 30% to 40%) is eliminated.

[0035] The dynamic freezing stage is an important step in making ice cream because this is the stage where crystallization of the ice cream occurs. During dynamic freezing, the ice cream mix is added to the ice cream machine between 0°C and 4°C (32°F and 39.2°F). As the refrigerant absorbs the heat in the mix, a layer of ice freezes onto the wall of the cold barrel, causing rapid nucleation, that is, the birth of small ice crystals.

[0036] To create small ice crystals during the dynamic freezing process, a high rate of nucleation, minimal growth, and minimal recrystallization are desired. A colder refrigerant temperature and a slower agitator speed can promote a higher rate of nucleation. A shorter residence time, a lower agitator speed, and a lower draw temperature can minimize growth and recrystallization.

[0037] Figure 2C shows the process of a rotary agitator, also called a mixer, impeller, blade, scraper, or paddle, that is used to scrape off the ice crystals formed on the cold barrel wall 22. The design and rotation of the rotary agitator direct the ice crystals formed on the cold barrel wall 22 towards the center of the barrel (bulk region) where the temperature is warmer and the size of the ice crystals is larger. As a result, some of the crystals melt and some recrystallize.

[0038] For a smooth and creamy ice cream, it is desirable to have rapid nucleation to form as many small ice crystals as possible. The more ice crystals formed during dynamic freezing, the more ice crystals are preserved during static freezing, leading to a smaller average size of the crystals and a smoother texture. If fewer crystals are formed during dynamic freezing or the nucleation rate is low, these crystals may ultimately grow to a significantly large size, resulting in a coarse texture.

[0039] Recrystallization during dynamic freezing can be divided into two zones: a wall region where the temperature of the barrel wall is cold enough for nucleation to occur, and a bulk region where the warmer temperature at the center of the barrel means that crystal growth and recrystallization, also known as ripening or coarsening, are dominant. The greater the degree of growth and recrystallization in the bulk region, the larger the ice crystals become. Recrystallization during ice cream freezing may be dominated by recrystallization and growth, and these mechanisms may become more important than nucleation in determining the final population of crystals. Therefore, minimizing growth and recrystallization is of utmost importance.

[0040] The residence time (the length of time the ice cream spends in the ice cream machine) can have a significant impact on the final ice crystal size distribution, and a shorter residence time produces an ice cream with smaller ice crystals due to reduced recrystallization. A longer residence time means that the ice cream reaches its dispense temperature (the temperature at which the ice cream is extracted from the ice cream machine) more slowly, around -5°C to -6°C (23°F to 21.2°F), which means the ice cream spends more time in the bulk zone where the warmer temperature causes rapid recrystallization. It may be advantageous to minimize the residence time of the ice cream in the ice cream machine by reaching the dispense temperature as quickly as possible. This can be achieved by mixing and cooling as quickly as possible.

[0041] Figure 2D shows the dependence of the take-out temperature on the ice crystal distribution of ice cream made with 28 D.E. (dextrose equivalent) corn syrup, a whisking speed of 500 RPM (revolutions per minute), and a flow rate of 34 liters per hour. The average diameter of the ice crystals increases from left to right along the horizontal axis, while the proportion of the ice cream containing this average diameter of ice crystal size increases from bottom to top on the vertical axis. As the take-out temperature decreases, the average diameter of the ice crystals in the ice cream also decreases.

[0042] For example, a recrystallization rate of 42 μm / day can be measured at -5 °C (23 °F). At this rate, an increase in ice crystal size of about 8 μm would be expected over a period of 10 minutes. This could correspond to an increase in ice crystal size at a slightly different temperature of -4 °C (24.8 °F). The longer the ice cream remains in the ice cream machine at a temperature where recrystallization occurs very rapidly, the greater the extent of recrystallization and the larger the ice crystals become.

[0043] Examining the effects of take-out temperature, whisking speed, and residence time on ice crystal size indicates that these aspects can potentially affect the final crystal size distribution.

[0044] The primary refrigerant (i.e., liquid ammonia or R-134a) is used in an ice cream machine to provide a temperature in the range of -23 °C to -29 °C (-9.4 °F to -20.2 °F), and the temperature of the barrel wall is a few degrees warmer. Lowering the refrigerant temperature promotes rapid heat removal at the barrel wall. Rapid heat removal enables a higher rate of ice nucleation, which results in smaller ice crystals as the number of smaller ice crystals is greater.

[0045] In the case of the size of ice crystals in the sorbet, a low refrigerant temperature (down to -19.9 °C (-3.82 °F)) may lead to a lower take-out temperature and a greater reduction in the length of the ice crystal chords. This is due to faster freezing, which causes faster formation of more ice crystals. A decrease in ice surface length as a function of evaporating temperature reduction can be observed.

[0046] The barrel wall temperature directly affects the cooling rate (the rate at which heat is removed from the ice cream mix), and thus the residence time. A lower wall temperature can more quickly lower the bulk temperature of the ice cream, shorten the residence time, and improve the ice crystal size distribution.

[0047] During dynamic freezing, the heat input from the blades of the rotating scraper due to friction and viscous dissipation at the barrel wall is significant and can account for up to about 50% of the total heat removed by the refrigerant. Accelerating the whisking speed can cause an increase in the ice cream temperature, leading to a large increase in the average ice crystal size. This is probably because the extra frictional heat generated by the blades melts many of the smallest crystals, resulting in a lower nucleation rate and enhanced recrystallization. Therefore, the whisking speed is usually limited to 100 - 200 RPM. Also, the large amount of frictional heat input by a higher whisking speed slows down the freezing process and leads to a longer residence time.

[0048] Occasionally, the movement of the rotating blades may not be sufficient to cause the fat globules in the ice cream mix to aggregate and partially adhere to each other, which is important for developing and maintaining small air bubbles in the ice cream. Emulsifiers in the ice cream mix serve to destabilize the fat globules so that they can aggregate with each other.

[0049] However, the rapidly rotating whisker and the rapid freezing process function of the machine described herein are sufficient to quickly develop a smooth and creamy ice cream, so the ice cream described herein does not require an emulsifier.

[0050] Furthermore, the ice cream described initially herein does not require a stabilizer because the ice cream does not need to be stored in a frozen state, and thus there is no need to use a stabilizer to enhance the melt resistance of the ice cream and extend the shelf life.

[0051] Even if a small amount of emulsifier and stabilizer can be added in some cases, developing an ice cream without emulsifier and stabilizer is an advantage of the ice cream described in this specification. An ice cream containing only milk, cream, and sugar without emulsifier and stabilizer is regarded as a "clean label" ice cream, which is an advantage of the ice cream mix described in this specification. A clean label refers to a food product with fewer and simpler ingredients, and the ingredients are from natural sources.

[0052] Figure 2D shows that the take-out temperature can have a significant impact on the average size of ice crystals, and a lower take-out temperature generally results in smaller ice crystals. Factors affecting the take-out temperature include refrigerant temperature, heat transfer, residence time, and overrun. Ice crystals may become larger at a take-out temperature of -3 to -6 °C (26.6 °F to 21.2 °F). When the take-out temperature is colder than -6 °C (21.2 °F), the average size of the ice crystals decreases. The smaller size of the ice crystals may be due to the lower refrigerant temperature required to obtain a lower take-out temperature.

[0053] Acceleration of the whisking speed may lead to an increase in the take-out temperature. For example, when the whisking speed is accelerated from 600 to 900 rpm, an increase in the take-out temperature of 1 °C (1.8 °F) may be observed due to the frictional energy transferred to the ice cream. Conversely, acceleration of the whisking speed may also lead to an increase in heat transfer at the barrel wall, resulting in a lower take-out temperature. As described above, the whisking speed is usually limited to 100 - 200 RPM.

[0054] However, the ice cream machines and processes described herein use a churn speed that varies from 100 to 1200 RPM during freezing to shorten the freezing time, reduce the ice crystal size, sometimes reducing it to less than 30 μm, with an average crystal size of less than 20 μm (19.1 μm) and no ice crystals over 40 μm. These characteristics may be similar to store-bought ice cream that has undergone a static freezing process (i.e., a hard pack process).

[0055] Also, a lower discharge temperature can be achieved through a longer residence time. However, as described above, a longer residence time means that the ice cream spends more time at temperatures where rapid growth and recrystallization occur, resulting in larger ice crystals. Since the residence time required to produce small ice crystals is shorter, the dynamic freezing step can account for incompatible phenomena, but a longer residence time gives a lower discharge temperature.

[0056] The discharge temperature has been observed to affect the average diameter of the ice crystals, followed by the mix flow rate, overrun, and churn speed (which determine the average residence time). When the discharge temperature is warmer than -5°C (23°F), the average diameter of the ice crystals is strongly dependent on the discharge temperature, with larger average ice crystals reported at warmer discharge temperatures. However, when the discharge temperature is colder than -5°C (23°F), not only the discharge temperature but also the overrun (the amount of air whipped into the ice cream) affects the average diameter of the ice crystals.

[0057] The difference in the average diameter of the ice crystals may not be significant when the discharge temperature is between -5°C and -6.5°C (23°F and 20.3°F) and the overrun is less than 70%. With more overrun, the average diameter of the ice crystals is often smaller. Increasing both the overrun and the churn speed can potentially form very small ice crystals. However, as described above, increasing the churn speed causes an increase in the product temperature, which leads to melting of the small crystals and enhanced recrystallization.

[0058] Some ice cream machines rotate the mixing paddle at a constant RPM during the freezing cycle and the dispensing cycle. Further, as described above, since the heat input from the rotating scraper blade can be significant, the rotational speed of the mixing paddle is typically kept low. For this reason, the whisk speed is typically limited to 100 - 200 RPM. Further, it is known that the large amount of frictional heat introduced by a higher whisk speed slows down the freezing process and results in a longer residence time.

[0059] Cooling is used to show the transfer of thermal energy, for example, to lower the temperature of the material contained within the pod. In some cases, cooling shows the transfer of thermal energy, for example, to lower the temperature of the material contained within the pod below the freezing point.

[0060] The systems and methods described herein describe a machine with a mixing paddle that rotates slowly at the beginning of the ice cream manufacturing process when the ice cream mix is liquid. In this state, increasing the amount of time the liquid touches the inner diameter of the pod wall helps to turn the ice cream mix from a liquid to ice. Using the evaporator of the ice cream machine, as the pod wall gets colder, the rotational speed of the mixing paddle increases to verify that the ice crystals are kept at a small size, preferably less than 30 μm.

[0061] The operation of accelerating the mixing paddle as the ice cream mix becomes increasingly viscous may not be intuitively understood. This is because the rotational speed of the mixing paddle is limited by the driving torque of the motor, and accelerating the mixing paddle as the ice cream mix becomes more viscous increases the torque required by the motor, which is not intuitively understood. This requires more output from the motor. Further, rotating the mixing paddle faster may damage an ice cream machine not designed for such speeds.

[0062] However, by accelerating the rotational speed of the mixing paddle in our machine, the machine can suck air into the pod. The process of sucking air into the pod in combination with the rotation of the mixing paddle helps to stir air into the frozen dessert, creating air bubbles in the frozen dessert. This process preferably results in an overrun of at least 30%.

[0063] The clean label ice cream mix packaged in the sterilized container or pod described herein can advantageously provide (i) natural ingredients, (ii) storage at room temperature as opposed to the need for refrigeration or freezing, and (iii) a long shelf life at room temperature, typically 6 to 9 months.

[0064] The ice cream machine for the pod of the clean label ice cream mix described herein can advantageously provide (i) ice cream with a smooth texture due to ice cream having very small ice crystals, often with an average diameter of less than 40 μm (and sometimes less than 30 μm), and (ii) delivery of the ice cream from room temperature to dispense in less than 3 minutes.

[0065] The ice cream produced using the machines described herein has, on average, much smaller ice crystal sizes and a much tighter standard deviation of ice crystal sizes than the corresponding product purchased in its stores. The ice cream machines described herein produce smoother ice cream, which is important because it does not require refrigeration or freezing before production for consumption. The ice cream used in these machines does not need to contain non-natural materials such as emulsifiers or stabilizers in the ice cream. The ice cream materials used with these machines are “clean label” and may simply contain milk, cream, sugar, and dry milk, and can be stored at room temperature for up to 9 months in a sterilized pod. The pod can simply be inserted into the machines described herein, and frozen ice cream is dispensed within minutes for the consumer to enjoy. These ice cream machines are designed to provide a useful interaction between the accelerating rotational speed of the mixing paddle and the design of the pod, and the rapid cooling characteristics of the evaporator and refrigeration system are integrated to enable this.

[0066] Some devices and methods for providing single-serving frozen confections include filling a pod with a low-acid liquid material having a pH level of 4.0 or greater, inserting the pod into a recess of a machine to provide a single-serving frozen confection, contacting the sidewall of the pod against the sidewall of the recess, cooling the recess with a refrigeration system of the machine, removing heat from the pod while connecting a motor of the machine to a motor of a mixing paddle inside the pod, moving the mixing paddle inside the pod during an increase in RPM over a freezing cycle to remove ice accumulation from the inner diameter of the pod, dispersing ice toward the center of the pod while mechanically agitating the ice into the remaining fluid, and simultaneously moving warmer fluid material from the center of the pod to the cooler inner diameter of the pod in contact with the recess of the machine to facilitate more rapid heat transfer.

[0067] Some devices and methods for providing a single-serving frozen confection having a temperature between 17 degrees Fahrenheit and 26° and having most of its ice crystals smaller than 50 μm and made in less than 5 minutes include filling a pod with a low-acid liquid material having a pH level of 4.0 or greater, inserting the pod into a recess of a machine to provide a single-serving frozen confection, contacting the sidewall of the pod against the sidewall of the recess, cooling the recess with a refrigeration system of the machine, removing heat from the pod while connecting a motor of the machine to a mixing paddle inside the pod, moving the mixing paddle inside the pod to remove ice accumulation from the inner diameter of the pod, dispersing ice toward the center of the pod while mechanically agitating the ice into the remaining fluid, and at the same time moving warmer fluid material from the center of the pod to the cooler inner diameter of the pod in contact with the recess of the machine to facilitate more rapid heat transfer.

[0068] These machine embodiments may include one or more of the following features.

[0069] In some embodiments, the mixing paddle rotates at at least 50 RPM at the beginning of the refrigeration cycle and increases to at least twice that during the refrigeration cycle.

[0070] In some embodiments, dispensing of the frozen confection occurs when its temperature is between 17 degrees Fahrenheit and 26 degrees Fahrenheit and the mixing paddle is rotating at greater than 100 RPM.

[0071] In some embodiments, filling of the low-acid liquid material having a pH level of 4.0 or greater is done before the pod is inserted into a recess of the machine to provide a single-serving frozen confection.

[0072] In some embodiments, the frozen confection is a low-acid food containing up to about 0.5% emulsifier and / or up to about 0.5% stabilizer. In some cases, the stabilizer may be sodium carboxymethyl cellulose (cellulose gum), guar gum, locust bean gum, sodium alginate, propylene glycol alginate, xanthan, carrageenan, modified starch, microcrystalline cellulose (cellulose gel), gelatin, calcium sulfate, propylene glycol monostearate, or other monoesters, and other thickeners such as these. In some cases, the emulsifier may be monoglycerides and diglycerides, distilled monoglycerides (saturated or unsaturated), polyoxyethylene sorbitan monostearate (60) or monooleate (80), and others. In some cases, the formulation of the ice cream mix may have a minimum stabilizer or no stabilizer.

[0073] In some embodiments, the pod may be a reusable pod for multiple uses.

[0074] In some embodiments, the pod has completed a retort sterilization process to enable room temperature storage of its low-acid material.

[0075] In some embodiments, the pod is aseptically filled and sealed to enable room temperature storage of the low-acid material.

[0076] In some embodiments, the mixing paddle is part of the machine.

[0077] In some embodiments, the pod is an aluminum beverage can.

[0078] In some embodiments, the pod is frustum-shaped.

[0079] In some embodiments, the frozen confection has an average ice crystal size of less than 30 μm.

[0080] In some embodiments, the ice cream formulation is considered a "clean label" that does not use stabilizing gums.

[0081] In some embodiments, the mixing paddle is helical, and the rotation of the paddle removes ice accumulation from the inner diameter of the pod and moves the frozen dessert downward.

[0082] In some embodiments, the mixing paddle is helical, and the rotation of the paddle removes ice accumulation from the inner diameter of the pod and moves the ice to the center of the pod while pushing warmer fluid from the center of the pod to the cooler inner diameter of the pod.

[0083] In some embodiments, the mixing paddle rotates, and the rotation speed of the paddle varies according to the changing viscosity of the frozen dessert within the pod.

[0084] In some embodiments, dispensing the frozen dessert from the pod into an edible cone or collection container while the pod is within a recess of the machine without the frozen dessert contacting another object.

[0085] In some embodiments, the mixing paddle forces the frozen dessert out of the pod.

[0086] In some embodiments, the recess of the machine may have an open position and a closed position, and the cooling of the pod occurs when the recess is in the closed position.

[0087] In some embodiments, the refrigeration system cools the pod with a compressor and uses a two-phase refrigerant fluid such as, for example, R22, R134A, R-600a, or R290. In some cases, the compressor is a reciprocating compressor. In some cases, the compressor is a rotary compressor. In some cases, the compressor is a direct current (DC) compressor. In some cases, the DC compressor has a variable motor speed to allow for an increase in displacement towards the demands of the refrigeration cooling cycle, for example, during the first 45 seconds of cooling the pod and as most of the refrigerated fluid evaporates, the motor speed is decelerated towards the end of the pod's cooling cycle. In some cases, the DC compressor has a variable motor speed that is adjusted according to the load on the refrigeration cycle of the machine.

[0088] The systems and methods described herein can provide various advantages.

[0089] Some of these features of these systems and methods allow for changing or accelerating the whisking speed during the freezing of ice cream in a single-serve pod. The rotational speed of the mixing panel will vary from 50 to 1200 RPM, shortening the freezing time and reducing the ice crystal size to less than about 50 μm.

[0090] Some of these systems use a low-temperature refrigerant such as R290, or R-600A needs to be used at a temperature (-7°C to -19.9°C) to effectively achieve the extraction temperature for achieving ice crystals less than 50 μm for most of a single-serve batch.

[0091] Some of these systems use a liquid ice cream mix that can be stored at room temperature for 9 to 12 months. This is achieved by performing a retort process where the sealed pod of the liquid ice cream mix is heated to 250°F for at least 5 minutes. By using non-pasteurized dairy products in our pods and performing a retort process on the pods before use, the dairy products inside the pods are pasteurized only once. This is in contrast to the typical pasteurization process shown in Figure 1, where dairy products are usually pasteurized before leaving the dairy factory, i.e., the dairy products are pasteurized twice, for example, once at the dairy factory and once in our retort process.

[0092] Even though it is generally preferred that retorting at a higher temperature would allow the pasteurization process to be completed in less time, some of these systems and processes use a retort process that retorts at 250°F. When the retort is completed at 250°F, the effect of browning can be limited when fructose is removed from the ice cream mix formulation. Completing the retort at 250°F can limit the effect of browning when removing fructose from the ice cream mix formulation.

[0093] Some of these features of these systems and methods lead to a compact machine. For example, a machine with a slide-type lid assembly is more compact than a system with a pop-up lid assembly. This approach can often easily accommodate a machine for home use on a kitchen countertop under the kitchen cabinet that is 18” away from the cooking surface. A machine with a paddle that mixes quickly and rotates at 100 to 1500 RPM or more can create a suction effect by drawing air into the container. Such a process does not require the use of a separate air supply and makes the overall system more compact than a system that injects air into the ice cream being formed.

[0094] Some of these systems and methods provide improved mixing. For example, a system having a mixing panel with off-center holes can produce a mixing effect that stirs the contents of a container better than a symmetric mixing paddle.

[0095] Some of these systems are user-friendly. For example, some machines do not require the user to align a pod (e.g., a can) inserted into the machine. In another example, a machine that does not require the user to manually pull down a lid to apply force to insert a plunger into a container is more accessible to the user without restricting force. Machines that provide this function without an additional motor tend to be more compact and simpler than machines that include a special motor to provide this function.

[0096] Some of these systems and methods provide operational advantages. For example, a machine having a refrigeration system with a heater and / or a hot gas bypass can reach a steady state quickly. This approach can improve performance and reduce waiting time. Some systems include a mixing motor that rotates a drive shaft continuously through cycles of mixing, shearing, and dispensing without reversing direction. This approach appears to reduce the likelihood that the mixing motor will stall as the viscosity of the pod contents increases with cooling.

[0097] Some systems include a shear cap designed to shear a protrusion of a container. A machine having such a shear cap can grip a pod more firmly during use, reducing the likelihood that the pod will slide. This can enhance the performance of the machine.

[0098] Some machines provide a vending machine-type dispensing function, enabling the machine to accept payment for ice cream, offer various ice cream flavors / options, and be easily used in a commercial environment.

[0099] For ease of explanation, terms such as "upward", "downward", "left", and "right" refer to the orientation of system components in the figures rather than implying absolute directions. For example, the movement of a drive shaft described as vertically upward or downward relative to the orientation of the system shown. However, such translational movement of the drive shaft depends on the orientation of the system and is not necessarily vertical.

[0100] Details of one or more embodiments of these systems and methods are set forth in the accompanying drawings and the following description. Other features, objects, and advantages of these systems and methods will be apparent from the description and drawings, and from the claims.

Brief Description of the Drawings

[0101]

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[0102] Similar reference symbols in the various drawings indicate similar elements.

Mode for Carrying Out the Invention

[0103] This specification describes systems and methods for rapidly cooling food and beverages. Some of these systems and methods use a countertop or installed machine to cool food and beverages in a container from room temperature to freezing in less than 3 minutes. For example, the techniques described herein have successfully demonstrated the ability to make soft serve, frozen coffee, frozen smoothies, and frozen cocktails from room temperature pods in about 90 seconds. This technique can also be used to make hard ice cream, milkshakes, frozen yogurt, and chilled probiotic drinks, to make frozen smoothies, frozen proteins, and other functional beverage shakes (e.g., collagen-based shakes, energy shakes, plant-based shakes, shakes without dairy components, and CDD shakes) for chilling cocktails, to make frozen coffee drinks and chilled coffee, with and without nitrogen therein. These systems and methods are based on a refrigeration cycle with low startup time and a pod-machine interface that provides easy use and highly efficient heat transfer. Some of the pods described can be sterilized (e.g., using retort sterilization or aseptic filling) and used to store materials, including dairy products, at room temperature for up to 18 months. These machines are described in detail by U.S. Patent Application No. 16 / 459,176 (Attorney Docket No. 47354-0009001), filed July 1, 2019, which is hereby incorporated by reference in its entirety.

[0104] An important challenge in the design of an ice cream machine is the ability to cool the pod as quickly as possible from room temperature to the dispense temperature, preferably within 2 minutes. Some machines reduce the dwell time that the ice cream remains in the ice cream machine by reaching the dispense temperature as quickly as possible. This can be achieved by mixing and cooling as quickly as possible.

[0105] The machines and processes described herein create ice cream where most of the ice crystals are less than 50 μm, and often most are less than 30 μm in a single-serve pod. For the ice cream to be dispensed from the pod into a bowl or dish without contacting the machine, the withdrawal or dispense temperature of the ice cream needs to be between -3° and -8°C (26.6°F to 17.6°F), preferably -3° to -8°C (26.6°F to 21.2°F).

[0106] The machines and processes described herein use a novel feature of accelerating the rotation speed during freezing and dispensing, which is counterintuitive. The machines described herein can use a mixing paddle that starts rotating slowly, but as the ice cream begins to freeze from liquid to solid, the rotation speed accelerates and much more power is required to overcome the increasing torque of the mixing paddle. Normally, as the torque increases, one would decelerate the rotation speed of the mixing paddle to keep the power requirements constant. In some machines, the rotation speed of the mixing paddle accelerates from 100 RPM to 1200 RPM during the freezing process to shorten the freezing time, reduce the ice crystal size, and make it smaller, about 50 μm.

[0107] Furthermore, by accelerating the rotation speed of the mixing paddle, the ice on the inner diameter of the pod melts, which is contrary to the intended function of the pod wall for quickly freezing the ice cream. The freezing time of the ice cream increases due to the extra friction caused by the high rotation speed of the mixing paddle melting the ice crystals on the pod wall. This is contrary to the typical goal of shortening the consumer waiting time for the ice cream to freeze and be dispensed. For at least these reasons, accelerating the rotation speed of the mixing paddle beyond a threshold of about 200 RPM is counterintuitive.

[0108] The rotational speed of the impeller mixing paddle is accelerated to draw air into the frozen dessert to achieve an overrun improvement (preferably at least 30% overrun). Also, the rotation of the helical outer shape of the mixing paddle (e.g., the helical outer shape of mixing paddle 950 is shown in FIG. 34A) generates a downward pressure to extrude the ice cream from the outlet port of the pod.

[0109] Furthermore, as described above, combining rapidly swirling the mixing paddle with rapidly cooling on the walls of the pod enables the cooled ice cream to be properly mixed within the pod and maintain a small ice crystal size that is directly correlated to the smoothness of the ice cream. This is, in part, to scrape the chilled ice cream off the walls of the pod and press the ice cream towards the warmer center of the pod. Optimal performance of the ice cream machine depends on both efficient cooling at the walls of the pod and rapid scraping / mixing of the contents of the pod. Machines with efficient cooling but no rapid scraping / mixing and vice versa would not be as optimal.

[0110] The ice cream mix described herein uses the novel feature of containing minimal or no stabilizers and emulsifiers. The absence or near absence of stabilizers, emulsifiers, and non-natural products is considered a "clean label". The ice cream mix described herein contains milk, sugar, and non-fat dry milk. By including these features in the ice cream mix, the resulting ice cream mostly has ice crystals less than 25 μm in diameter.

[0111] For example, a clean label formulation for a 150 g ice cream serving may contain the following ratios, namely 48 g whole milk, 67 g heavy cream (without gums), 24 g refined sugar, and 11 g non-fat dry milk.

[0112] FIG. 3A is a perspective view of a machine 100 for cooling food or drink. FIG. 3B shows the machine without its housing. Machine 100 lowers the temperature of the material within a pod containing the material. Most pods include a mixing paddle used to mix the material before dispensing the cooled or frozen product. In some examples, the mixing paddle is part of the machine and may be inserted into the pod. In some examples, the mixing paddle can be reused multiple times. In some examples, the machine does not dispense frozen treats, in which case the frozen treats can be scooped out of the pod using a spoon.

[0113] Machine 100 includes a body 102 that includes a compressor, a condenser, a fan, an evaporator, a capillary tube, a control system, a lid system, and a dispensing system having a housing 104 and a pod-machine junction 106. The pod-machine junction 106 includes an evaporator 108 of a refrigeration system 109 in which other components are disposed within the housing 104. As shown in FIG. 3B, the evaporator 108 defines a receptacle 110 sized to receive a pod.

[0114] The lid 112 is attached to the housing 104 via a hinge 114. The lid 112 is rotatable between a closed position that covers the receptacle 110 (FIG. 3A) and an open position that exposes the receptacle 110 (FIG. 3B). The lid 112, in its closed position, covers the receptacle 110 and is locked in place. Within machine 100, a latch 116 on the lid 112 engages a latch recess 118 on the pod-machine junction. A latch sensor 120 is disposed in the latch recess 118 to determine whether the latch 116 is engaged with the latch recess 118. A processor 122 is electrically connected to the latch sensor 120 and recognizes that the lid 112 is closed when the latch sensor 120 determines that the latch 116 and the latch recess 118 are engaged. Not all machines include a latch sensor.

[0115] The auxiliary cover 115 rotates upward as the lid 112 moves from its closed position to its open position. The slot in the auxiliary cover 115 receives the handle of the lid 112 during this movement. In some auxiliary covers, the lid slides into the housing when the lid moves to the open position.

[0116] Within the machine 100, the evaporator 108 is fixedly positioned relative to the main body 102 of the machine 100, and access to the receptacle 110 is provided by movement of the lid 112. In some machines, the evaporator 108 is displaceable relative to the main body 102, and movement of the evaporator 108 provides access to the receptacle 110.

[0117] A motor 124 disposed within the housing 104 is mechanically connected to a drive shaft 126 extending from the lid 112. When the lid 112 is in its closed position, the drive shaft 126 extends into the receptacle 110 and engages the pod, if present, to move one or more paddles within the pod. The paddles may be referred to as impellers, blades, frothers, or mixing paddles. The processor 122 is in electronic communication with the motor 124 and controls the operation of the motor 124.

[0118] In some machines, the shaft associated with the paddle(s) of the pod extends outward from the pod, and the lid 112 has a rotary receptacle (instead of the drive shaft 126) that is mechanically connected to the motor 124. In some machines, the motor provides at least 50 ozf-in (ounce-force inch) of torque at a rotational speed of at least 100 RPM (revolutions per minute) with the mixing paddle. For example, a torque of 100 ozf-in and a rotational speed of 750 RPM may be used. In some machines, the motor of the mixing paddle provides a maximum torque of 400 ozf-in and a maximum rotational speed of 1,500 RPM.

[0119] Figure 3C is a perspective view of the cover 112 shown separately so that the belt 125 extending from the motor 124 to the drive shaft 126 can be seen. Referring again to Figure 3B, the motor 124 is attached to a plate that moves along the rail 127. The plate can move approximately 0.25 inches to adjust the tension of the belt 125. During assembly, the plate slides along the rail. A spring disposed between the plate and the cover 112 deflects the cover 112 away from the plate to maintain the tension of the belt.

[0120] Figure 4A is a perspective view of the covered machine 100 of the pod-machine joint 106 shown as being transparent to enable a more detailed view of the evaporator 108. Figure 4B is a plan view of a part of the machine 100 without the housing 104 and the pod-machine joint 106 without the cover 112. Figures 4C and 4D are, respectively, a perspective view and a side view of the evaporator 108. The evaporator 108 is described in detail in U.S. Patent Application No. 16 / 459,388 (Attorney Docket No. 47354-0006001), filed on July 1, 2019, the entire disclosure of which is incorporated herein by reference.

[0121] The evaporator 108 has a foldable configuration in which a first portion 128 is attached to a second portion 130 by a living hinge 132 on one side and is separated by a gap 134 on the other side. Refrigerant flows from other components of the refrigeration system through the fluid channel 136 (best seen in Figure 4B) into the evaporator 108. The refrigerant flows through the evaporator 108 in the internal channel through the first portion 128, the living hinge 132, and the second portion 130.

[0122] The space 137 (best seen in Figure 4B) between the outer wall of the evaporator 108 and the inner wall of the housing of the pod-machine joint 106 is filled with an insulating material to reduce heat exchange between the environment and the evaporator 108. In the machine 100, the space 137 is filled with an aerosol (not shown). Some machines use other insulating materials such as annuli (voids, etc.), insulating foams made from various polymers, fiberglass wool, etc.

[0123] Evaporator 108 has an open position and a closed position. In the open position, gap 134 is open, providing a void between the first portion 128 and the second portion 130. Within machine 100, the first portion 128 and the second portion 130 are both pushed together in the closed position.

[0124] The inner diameter ID of evaporator 108 is slightly larger in the open position than in the closed position. The pod can be inserted into and removed from evaporator 108 while the evaporator is in its open position. After the pod is inserted, when evaporator 108 is transitioned from its open position to its closed position, evaporator 108 is tightened around the outer diameter of the pod. For example, machine 100 is configured to use a pod with an outer diameter of 2.085”. Evaporator 108 has an inner diameter of 2.115” in the open position and an inner diameter of 2.085” in the closed position. Evaporator 108 has an inner diameter of 2.115 inches in its open position and an inner diameter of 2.085 inches in its closed position. Some machines are sized and configured with evaporators to cool other pods.

[0125] The evaporator is sized to easily receive the pod in the open position and engage the pod in the closed position. Instead of a collapsible configuration, some evaporators may have multiple parts that slide towards each other to have open and closed positions, rather than moving on a hinge. Some evaporators may be frustoconical in shape. Some evaporators may have tubes connecting cooling channels between various parts of the evaporator. Some evaporators have a first portion and a second portion, where the first portion and the second portion are pushed towards each other, reducing the gap between them, but the space between the first portion and the second portion exists in the closed position.

[0126] Some machines are sized and configured to cool other pods and have an evaporator. The pods can be formed, for example, from the size of a commercially available can. A "slim" can has a diameter ranging from 2.080 inches to 2.090 inches and a volume of 180 milliliters (ml) to 300 ml. A "streamlined" can has a diameter ranging from 2.250 inches to 2.400 inches and a volume of 180 ml to 400 ml. A "standard" size can has a diameter ranging from 2.500 inches to 2.600 inches and a volume of 200 ml to 500 ml. Machine 100 is configured to use pods having an outer diameter of 2.085 ± 0.10 inches. Some pods have an inner diameter from 2.065 inches to 2.075 inches to allow a mixing paddle having a diameter of 2.045 - 2.055 inches to rotate at RPMs from 100 to 1,500 RPM, and 6,000 to 93,000 square inches are rubbed off per minute.

[0127] For an inner diameter of approximately 2.085 inches, the pod can accommodate a mixing paddle with a diameter of approximately 2.065 inches. The mixing paddle can rotate within the pod at a rotational speed between 100 RPM and 1,500 RPM. During this time, the single blade edge of the mixing paddle rubs off the inner wall of the pod at a speed ranging from 3,100 to 46,500 square inches per minute. The area rubbed off per minute is multiplied at each rubbing edge of the mixing paddle (i.e., a mixing paddle with two edges will rub off approximately 6,200 to 93,000 square inches per minute). As described above, this rubbing and mixing process helps to disperse the ice crystals formed on the wall of the pod into the interior of the pod.

[0128] Some pods are pressurized to have an internal pressure of about 5 - 100 psi gauge pressure. Some pods have a decorative outer coating with a thickness of 10 - 50 microns or less (e.g., less than 50 microns). A thicker outer coating can insulate the pod and may prevent heat transfer during cooling of the pod. Some pods do not have an inner or outer coating at the ends.

[0129] In addition to cylindrical pods, some pods are frustoconical (e.g., frustoconical with an open end). Since the frozen confection can be scooped out with a spoon from the open end of the pod, some pods do not require a dispensing port.

[0130] In addition to disposable pods, some pods are reusable. Some pods are used, washed, and reused. Some pods are purchased empty and filled before use. Some pods are purchased or obtained full, used, and refilled by the user or by a machine. Some pods are sterilized after use and after refilling to allow storage at room temperature. Some pods include a resealing feature that allows the pod to be refilled and resealed. Some pods include a reusable protrusion for dispensing the frozen confection from the pod into a machine. Some pods can be purchased empty and used with a home ice cream making kit using clean label ingredients.

[0131] The closed position of the evaporator 108 improves heat transfer between the inserted pod 150 and the evaporator 108 by increasing the contact area between the pod 150 and the evaporator 108 and reducing or eliminating the gap between the wall of the pod 150 and the evaporator 108. In some pods, the pressure applied to the pod by the evaporator 108 is counteracted by a mixing paddle, a pressurized gas within the pod, or both, to maintain the shape of the pod housing. The evaporator 108 can provide a closing force of about 10 - 50 lbf (pound - force) and an approximate torque clamping force of 1,000 - 1,500 ozf - in on the pod 150.

[0132] In evaporator 108, the relative positions of the first portion 128 and the second portion 130, as well as the size of the gap 134 therebetween, are controlled by two bars 138 connected by bolts 140 and two springs 142. Each of the bars 138 has a threaded central hole through which the bolt 140 extends and two end holes for engaging the pins 144. Each of the two springs 142 is disposed around the pin 144 that extends between the bars 138. Some machines use other systems for controlling the size of the gap 134, such as a cable - based perimeter cable system that extends around the outer diameter of the evaporator 108, where the cable is tensioned against the pins to close the evaporator 108 and loosened to open the evaporator 108. In other evaporators, there are multiple bolts and end holes, one or more springs, and one or more engaging pins.

[0133] One bar 138 is attached to the first portion 128 of the evaporator 108, and the other bar 138 is attached to the second portion 130 of the evaporator 108. In some evaporators, the bars 138 are integral with the body of the evaporator 108 instead of being attached to the body of the evaporator. The springs 142 push the bars 138 away from each other. The spring force deflects the first portion 128 and the second portion 130 of the evaporator 108 away from each other at the gap 134. Rotation of the bolt 140 in one direction increases the force pushing the bars 138 towards each other, and rotation of the bolt in the opposite direction decreases this force. When the force applied by the bolt 140 is greater than the spring force, the bars 138 bring together the first portion 128 and the second portion 130 of the evaporator.

[0134] Machine 100 includes an electric motor 146 (shown in FIG. 4B) that operates to rotate bolt 140 to control the size of gap 134. Some machines use other mechanisms to rotate bolt 140. For example, some machines use a mechanical linkage mechanism between, for example, lid 112 and bolt 140 to rotate bolt 140 when lid 112 is opened and closed. Some machines include a handle that can be attached to the bolt to manually tighten or loosen the bolt. Some machines have a wedge system that forcibly positions the bar in the closed position when the lid of the machine is closed. This technique may be used in place of electric motor 146 or may be provided as a backup in the event of motor failure.

[0135] Electric motor 146 communicates with and is controlled by processor 122 of machine 100. Some electric drives include a torque sensor that transmits torque measurement values to the processor. For example, when a pod sensor indicates that a pod is disposed within receptacle 110, or when latch sensor 120 indicates that lid 112 and pod-machine junction 106 are engaged, processor 122 sends a signal to the motor to rotate bolt 140 in a first direction to push bar 138 together. It is desirable for the foldable evaporator to be closed and for the pod to be held in a firmly fixed position before the lid is closed, with the shaft passing through the pod and engaging the mixing paddle. This positioning may be important for shaft-mixing paddle engagement. Processor 122 sends a signal to the electric drive to rotate bolt 140 in a second direction, for example, after the food or drink being produced has been cooled / frozen and dispensed from machine 100, thereby opening evaporator gap 134 and allowing easy removal of pod 150 from evaporator 108.

[0136] The base of the evaporator 108 has three holes 148 (see FIG. 4C) that are used to attach the evaporator 108 to the floor surface of the pod - machine joint portion 106. All three of the holes 148 extend through the base of the second portion 130 of the evaporator 108. The first portion 128 of the evaporator 108 is not directly attached to the floor surface of the pod - machine joint portion 106. This configuration allows for the opening and closing movement described above. Other configurations that allow for the opening and closing of the evaporator 108 can also be used. Some machines have more or fewer than three holes 148. Some evaporators are attached to components other than the floor surface of the pod - machine joint portion, such as a dispensing mechanism.

[0137] Many factors affect the performance of the refrigeration system. Important factors include the mass velocity of the refrigerant flowing through the system, the refrigerant wetted surface area, the refrigeration process, the area of the pod / evaporator heat transfer surface, the mass of the evaporator, and the thermal conductivity of the material of the heat transfer surface. Extensive modeling and experimental studies in the development of the prototype system described herein have determined that the appropriate selection of the mass velocity of the refrigerant flowing through the system and the refrigerant wetted surface area are the most important parameters for balancing to provide a system capable of freezing up to 10 - 12 ounces of confectionery in less than two minutes.

[0138] The evaporator described herein has the following characteristics.

Table 2

[0139] The mass velocity describes the refrigerant flowing through the evaporator with polyphase properties. The two-phase process utilizes a large amount of heat that is absorbed and consumed when the refrigerant fluid (e.g., R-290 propane) changes its state from liquid to gas and from gas to liquid, respectively. The rate of heat transfer depends, in part, on exposing the inner surface of the evaporator to the new liquid refrigerant to vaporize and cool the liquid ice cream mix. To do this, the velocity of the refrigerant fluid must be fast enough so that the vapor creates a channel or flows down the center of the flow path in the wall of the evaporator and the liquid refrigerant is pushed through these channel passages in the wall. One approximate measure of the fluid velocity in a refrigeration system is the mass velocity - the mass flow rate of the refrigerant within the system per unit cross-sectional area of the flow path in units of pounds per hour per square foot (lb / hr ft 2 ). The velocity (ft / s), measured in feet per second, constantly changes as the fluid flow changes state from liquid to gas, and it is difficult to apply the "more familiar method of measuring velocity" in a two-phase system. When the liquid refrigerant constantly sweeps the entire evaporator wall, the liquid refrigerant may vaporize, and the new liquid may be pressed against the wall of the cooling channel when the "center part" of the vapor flows down the center of the passage. At low speeds, the flow separates based on gravity, with the liquid remaining at the bottom of the cooling channels in the evaporator and the vapor rising to the upper side of the cooling channel. For example, if the amount of the area exposed to the liquid is halved, this will approximately reduce the amount of heat transfer by half.

[0140] According to the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE), a mass velocity of 150,000 lb / ft^2 maximizes the performance of most of the evaporator flow channels. The mass velocity is one of the parameters that must be balanced to optimize the refrigerant system. The parameters that affect the performance of the evaporator are the mass flow rate, the convective heat transfer coefficient, and the pressure drop. The nominal operating pressure of the evaporator is determined by the required temperature of the evaporator and the properties of the refrigerant used in the system. The mass flow rate of the refrigerant through the evaporator must be high enough for the refrigerant to absorb the amount of thermal energy from the confectionery in a given amount of time and freeze it. The mass flow rate is mainly determined by the size of the compressor. To reduce cost, weight, and size, it is desirable to use the smallest possible compressor. The convective heat transfer coefficient is affected by the mass velocity of the evaporator and the wetted surface area. The convective heat transfer coefficient increases as the mass velocity accelerates. However, the pressure drop also increases with the mass velocity. This increases the power required to operate the compressor next, and decreases the mass flow rate that the compressor can deliver. It is desirable to design the evaporator to meet the performance goals while using the least expensive compressor possible. We have determined that an evaporator with a mass flow rate of 75,000 - 125,000 lb / hr ft^2 is effective in helping to provide a system that can freeze up to 12 ounces of confectionery in less than 2 minutes. The latest prototype has a mass flow rate of approximately 100,000 lb / hr ft^2 and provides an excellent balance of a high mass velocity, a manageable pressure drop (less than 2 psi) in the system, and a compressor sized appropriately with a drainage volume of less than 12 cc.

[0141] In some systems, the refrigeration system cools the pod with a compressor using a two-phase refrigerant fluid such as R134A, R22, R600a, or R290. In some systems, the compressor is a reciprocating compressor or a rotary compressor. A direct current (DC) compressor with variable motor speed allows for an increase in displacement towards the start of the refrigeration cycle of the pod (e.g., the first 45 seconds of cooling of the pod) to increase the efficiency of the refrigeration process while maintaining a pressure drop, and decelerates the motor speed towards the end of the cooling system of the pod. In some systems, the DC compressor may have a variable motor speed that is adjusted according to the load on the refrigeration cycle of the machine.

[0142] In some systems, the use of natural refrigerants such as R290 can help achieve the objectives of international protocols such as the Montreal and Kyoto Protocols and reduce environmental problems such as ozone layer depletion and global warming. These protocols and environmental problems generally suggest a phased reduction of R22 and R134A.

[0143] The thermophysical properties of the refrigerant determine the energy performance of the refrigeration system. The following table shows the thermophysical properties of refrigerants R22 and R290 at an evaporation temperature of 10°C and a condensation temperature of 45°C.

Table 3

[0144] The lower liquid density of the R290 refrigerant indicates a lower requirement for refrigerant mass, resulting in lower friction and better heat transfer coefficients in the evaporator and condenser. Refrigerant viscosity is a major cause of irreversibility and affects the condensation heat transfer coefficient and the boiling heat transfer coefficient. R290 has a lower viscosity and a higher thermal conductivity that improves the performance of the condenser and evaporator. The higher the specific heat of R290, the lower the discharge temperature.

[0145] Another important factor affecting the performance of the evaporator is the surface area of the refrigerant-wetted surface, which is the area of all the cooling channels within the evaporator, as long as at least some liquid refrigerant is present through these channels. Increasing the wetted surface area can improve the heat transfer characteristics of the evaporator. However, increasing the wetted surface area may increase the mass of the evaporator, which will increase the thermal inertia of the evaporator and reduce the heat transfer characteristics.

[0146] The amount of heat that can be transferred from within the liquid in the pod is the ice cream mix that is proportional to the surface area of the pod / evaporator heat transfer surface. The larger the surface area, the more desirable, but increasing the surface area may require an increase in the mass of the evaporator that will reduce the heat transfer characteristics of the evaporator. We have determined that an evaporator with a pod / evaporator heat transfer surface area between 20 and 40 square inches, when effectively combined with other features and effects, serves to provide a system that can freeze up to 12 ounces of confectionery in less than 2 minutes.

[0147] The heat transfer rate is an inherent property of the material that relates its ability to conduct heat. Heat transfer by conduction involves the transfer of energy within the material without the movement of the material as a whole. An evaporator with walls made of a high thermal conductivity material (e.g., aluminum) reduces the temperature difference across the walls of the evaporator. Reducing this temperature difference reduces the work required for the refrigeration system to cool the evaporator to the correct temperature.

[0148] The temperature of the pod can be measured using a temperature sensor such as a thermocouple. In some machines, a thermocouple that physically contacts the outer surface of the pod can be used to measure the temperature of the pod, or the thermocouple can be provided directly outside the pod. In some machines, the sensor(s) radially penetrate the evaporator and in some cases are spring - loaded to ensure a consistent force at the sensor tip. The sensor may be thermally insulated from the evaporator such that the sensor senses only the temperature outside the pod. The pod may be made of aluminum with a thickness of about 0.004 - 0.008 inches such that the pod temperature is substantially the same as the temperature of the contents. Using these temperatures, the process can be controlled in several ways, namely (i) by varying the mixer speed depending on how quickly the product freezes, (ii) by stopping the freezing process when the target temperature is reached, and (iii) during the dispensing process, by sensing when the pod is empty and ending the dispensing process at that time instead of rotating the mixing paddle in the empty pod which could be noisy.

[0149] For the desired heat transfer to occur, the evaporator must be cooled. The greater the mass of the evaporator, the longer the time required for this cooling. Reducing the evaporator mass decreases the amount of material that must be cooled during the refrigeration cycle. An evaporator with a large mass increases the time required to freeze up to 12 ounces of confectionery.

[0150] The effects of thermal conductivity and mass can be balanced by an appropriate choice of materials. There are materials such as copper that have a higher thermal conductivity than aluminum. However, the density of copper is greater than the density of aluminum. For this reason, several evaporators have been constructed that use high - thermal - conductivity copper only at the heat - exchange surface of the evaporator and aluminum everywhere else.

[0151] Figures 5A-5F show the components of the pod-machine interface 106 that operates to open a pod within the evaporator 108 to dispense a food or beverage being produced by the machine 100. This is an example of one technique for opening a pod, although some machines and associated pods use other techniques.

[0152] Figure 5A is a partial cutaway schematic view of the pod-machine interface 106 with the pod 150 placed within the evaporator 108. Figure 5B is a schematic top plan view showing the relationship of the end of the pod 150 to the floor 152 of the pod-machine interface 106. The floor of the pod-machine interface 106 is formed by the dispenser 153. Figures 5C and 5D are perspective views of the dispenser 153. Figures 5E and 5F are perspective views of the insert 154 disposed within the dispenser 153. The insert 154 includes an electric motor 146 that operates to drive the floor 152 of the worm gear 157 of the pod-machine interface 106. The worm gear 157 is engaged with a gear 159 having an annular configuration. An annular member 161 attached to the gear 159 extends from the gear 159 into the interior region of the pod-machine interface 106. The annular member 161 has a protrusion 163 configured to engage a pod inserted into the pod-machine interface 106 to open the pod. The protrusion 163 of the annular member 161 is four dowel-shaped protrusions. Some annular gears may have more or fewer protrusions, and the protrusions may have other shapes, such as "teeth" for example.

[0153] Pod 150 includes a body 158 that includes a mixing paddle 160 (see FIG. 5A). The pod 150 also has a base 162 that defines a cap 166 extending across an opening 164 and the base 162 (see FIG. 5B). The base 162 is joined / fixed onto the body 158 of the pod 150. The base 162 includes a protrusion 165. The cap 166 attached onto the base 162 is rotatable about the outer periphery / axis of the pod 150. In use, when the product is ready to be dispensed from the pod 150, the dispenser 153 of the machine engages and rotates the cap 166 about the first end of the pod 150. The cap 166 engages the protrusion 165 and is rotated to a position for separating from the rest of the base 162. The pod 150 and its components are described in more detail with respect to FIGS. 8A - 8B.

[0154] The opening 164 within the base 162 is opened by the rotation of the cap 166. The pod - machine interface 106 includes an electric motor 146 having a through - plate that engages the outer periphery of a gear 168. By the operation of the electric motor 146, the gear 168 rotates. The gear 168 is attached to an annular member 161, and the rotation of the gear 168 rotates the annular member 161. Both the gear 168 and the annular member 161 are annular and together define a central hole through which food or drink can be dispensed from the pod 150 through the opening 164 without contacting the gear 168 or the annular member 161. When the pod 150 is placed on the evaporator 108, the annular member 161 engages the cap 166, and the rotation of the annular member 161 rotates the cap 166.

[0155] FIG. 6 is a schematic view of a refrigeration system 109 including an evaporator 108. The refrigeration system also includes a condenser 180, a suction line heat exchanger 182, an expansion device 184, and a compressor 186. The expansion device 184 may include a valve or a capillary tube that could both be used in the refrigeration system 109. High-pressure liquid refrigerant flows from the condenser 180 to the evaporator 108 through the suction line heat exchanger 182 and the expansion device 184. The expansion device 184 restricts the flow of the liquid refrigerant fluid and reduces the pressure of the liquid refrigerant as it exits the expansion device 184. The low-pressure liquid then moves to the evaporator 108 where heat is absorbed from the pod 150, and the contents within the evaporator 108 change the refrigerant from a liquid to a gas. The vapor-phase refrigerant flows from the evaporator 108 to the compressor 186 through the suction line heat exchanger 182. In the suction line heat exchanger 182, the low-temperature vapor leaving the evaporator 108 precools the liquid leaving the condenser 180. The refrigerant enters the compressor 186 as a low-pressure gas and leaves the compressor 186 as a high-pressure gas. The gas then flows to the condenser 180 where heat exchange cools the refrigerant and condenses the refrigerant to a liquid.

[0156] The refrigeration system 109 includes a first bypass line 188 or valve, and a second bypass line 190 or valve. The first bypass line 188 directly connects the discharge of the compressor 186 to the inlet of the compressor 186. Disposed in both the first bypass line and the second bypass line are bypass valves that open and close passages to allow for a bypass flow of the refrigerant. By diverting the refrigerant directly from the compressor discharge to the inlet, defrosting and temperature control of the evaporator can be provided without injecting hot gas into the evaporator. Also, the first bypass line 188 provides a means for rapid pressure equalization across the compressor 186 that enables rapid restart (i.e., quickly freezing pods one after another). The second bypass line 190 allows for applying warm gas to the evaporator 108 to defrost the evaporator 108. The bypass valve may be, for example, a solenoid valve or a throttle valve. An additional bypass valve (not shown) can be used to direct warm air along the length of the mixing paddle 160 to help remove product adhering to the mixing paddle 160.

[0157] Figures 7A and 7B are diagrams of a prototype condenser 180. The condenser has internal channels 192. The internal channels 192 interact with the refrigerant to increase the surface area for rapidly cooling the refrigerant. These images show microchannel tubing, which has small channels that maintain the coolant velocity, thin walls for good heat transfer, and is used because it has little mass to prevent the condenser from becoming a heat sink.

[0158] Figures 10A and 10B show an example of a pod 150 for use with the machine 100 described with respect to FIGS. 3A - 5F. FIG. 8A is a side view of the pod 150. FIG. 8B is a schematic side view of the pod 150 and a mixing paddle 160 disposed in the body 158 of the pod 150.

[0159] The pod 150 is sized to fit into the receptacle 110 of the machine 100. The pod can be sized to provide a single - serving of food or drink being produced. Typically, the pod has a volume between 6 fluid ounces and 18 fluid ounces. The pod 150 has a volume of approximately 8.5 fluid ounces.

[0160] The body 158 of the pod 150 is an aluminum beverage can that includes a mixing paddle 160. The body 158 extends from a first end 210 to a second end 212 at the base and has a circular cross - section. The first end 210 has a diameter D LE that is slightly larger than the diameter D UE of the second end 212. This configuration facilitates stacking a plurality of pods 150 on top of each other, with the first end 210 of one pod receiving the second end 212 of another pod.

[0161] The side wall 214 connects the first end 210 to the second end 212. The wall 214 has a first neck 216, a second neck 218, and a barrel 220 between the first neck 216 and the second neck 218. The barrel 220 has a circular cross - section with a diameter D B . The diameter D B is the diameter D of the first end 210UE and the diameter D of the second end 212 LE is larger than both. The first neck 216 connects the barrel 220 to the first end 210, and the first neck 216 has a smaller diameter D UE to a larger diameter D B and slopes as it extends into the barrel. The second neck 218 connects the barrel 220 to the second end 212, and the second neck 218 has a larger diameter D of the barrel 220 B to a smaller diameter D of the second end 212 LE and slopes as it extends. Since the second end 212 has a smaller diameter than the first end 210, the second neck 218 has a steeper slope than the first neck 216.

[0162] This configuration of the pod 150 provides an increase in material usage, i.e., the ability to use more base material (e.g., aluminum) per pod. This configuration further supports the columnar strength of the pod.

[0163] The pod 150 is designed for good heat transfer from the evaporator to the contents of the pod. The body 158 of the pod 150 is made of aluminum and is between 5 microns and 50 microns thick. The bodies of some pods are made of other materials, such as various polymers like tin, stainless steel, and polyethylene terephthalate (PTE).

[0164] The pod 150 may be made from a combination of different materials to assist in the manufacturability and performance of the pod. In one embodiment, the pod wall and the second end 212 may be made of aluminum 3104, and the base may be made of aluminum 5182.

[0165] In some pods, the internal components of the pod are coated with lacquer to prevent corrosion of the pod when it comes into contact with the materials contained within the pod. Also, this lacquer reduces the likelihood of "off-notes" of metals in the food and beverage materials contained within the pod. For example, aluminum pods can be coated internally with one or a combination of the following coatings, namely Sherwin Williams / Valspar V70Q11, V70Q05, 32SO2AD, 40Q60AJ, PPG Innovel2012-823, 2012-820C, and / or Akzo Nobel Aqualure G150. Also, other coatings made by the same or other coating manufacturers can be used.

[0166] Some mixing paddles are made of similar aluminum alloys and are coated with similar lacquers / coatings. For example, Whitford / PPG coating 8870 can be used as a coating for mixing paddles. The lacquer on the mixing paddle can have the advantages of additional anti-sticking and hardening. Some mixing paddles are made from AL5182-H48 or other aluminum alloys. Some mixing paddles exhibit a tensile strength of 250 - 310 MPa minimum, a yield strength of 180 - 260 MPa minimum, and an elongation at break of 4% - 12%.

[0167] In some machines, the mixing paddle may be removable from the pod, the mixing paddle can be washed, and the mixing paddle can potentially be reused by reinstalling it in the same pod or another pod.

[0168] In addition to the functionality of the mixing paddles described above, some machines oscillate and / or vibrate the mixing paddles to help remove the product adhering to the mixing paddles. This technique can be enabled by a machine (such as machine 100) that includes a solenoid for oscillating and / or vibrating the mixing paddle.

[0169] Other pod - machine coupling portions that can be used with this machine and similar machines are described in detail by U.S. Patent Application No. 16 / 459,322 (Attorney Docket No. 47354 - 0010001), filed on July 1, 2019, which is hereby incorporated by reference in its entirety.

[0170] Some pods include a seal configured to break when torque is applied by a mixing motor. Such pod designs may be easier and less expensive to manufacture for compatibility with the machine.

[0171] Figures 9A through 9C show the engagement between the drive shaft 126 of the machine 100 and the mixing paddle 160 of the pod 150 inserted into the machine 100. Figures 9A and 9B are perspective views of the pod 150 and the drive shaft 126. In use, the pod 150 has its first end 210 inserted into the receptacle 110 of the evaporator 108 in a downward orientation. This orientation exposes the second end 212 of the pod 150 to the drive shaft 126, as shown in Figure 9A. Closing the lid 112 (see Figure 3A) causes the drive shaft 126 to be pressed against the second end 212 of the pod 150 with sufficient force to penetrate the second end 212 of the pod 150. In some machines, the downward force of the penetration operation of the drive shaft 126 into the second end 212 of the pod 150 is about 50 lbf. A downward force between 15 and 65 lbf is effective in penetrating the second end of the pod without damaging other parts of the pod.

[0172] Figure 9B shows the resulting holes and the mixing paddle 160 visible through the holes. The drive shaft 126 is shown offset for clarity. Figure 9C is a cross-sectional view of a portion of the pod 150 with the drive shaft 126 engaged with the mixing paddle 160 after the lid is closed. Normally, there is no sealing seal between the drive shaft 126 and the pod 150, and thus air can flow in when the frozen confection is discharged / distributed from the other end of the pod 150. In an alternative embodiment, there is a sealing seal, and thus the pod 150 holds pressure to enhance the contact between the pod 150 and the evaporator 108.

[0173] Some mixing paddles include a funnel or receptacle configuration that receives the pierced end of the second end of the pod when the second end is pierced by the drive shaft.

[0174] Figure 10A shows the first end 210 of the pod 150 with the cap 166 spaced apart from the base 162 for clarity. Figures 11A through 11G show the rotation of the cap 166 around the first end 210 of the pod 150 to cut away and remove the protrusion 165 of the base 162 and expose the opening 164 extending through the base 162.

[0175] The base 162 is manufactured separately from the body 158 of the pod 150 and is then attached (e.g., by crimping or splicing) to the body 158 of the pod 150 that covers the open end of the body 158. The protrusion 165 of the base 162 can be formed, for example, by punching, deep drawing, or heading of the thin aluminum sheet used to form the base. The protrusion 165 is attached to the remainder of the base 162, for example, by weakened score lines 173. The scoring can be a vertical score into the base of the aluminum sheet or a horizontal score into the wall of the protrusion 165. For example, the material can be scored from an initial thickness of 0.008 inches to 0.010 inches (e.g., the initial thickness can be 0.008 inches) to a post-scoring thickness of 0.001 inches to 0.008 inches (e.g., the score thickness can be 0.002 inches).

[0176] FIG. 10B shows a cross-sectional view of the first end 210 of the pod 150 showing the base 162, the protrusion 165, and the weakened score line 173. The weakened score line 173 is 0.006 inches deep into the aluminum base lid material that is 0.08 inches thick.

[0177] In some embodiments, there is no scoring after punching, but rather the wall is intentionally made thin to facilitate rupture. In another version, there is no variable wall thickness, but rather the cap 166 combined with the force of the machine dispensing mechanism engagement is sufficient to cut a wall thickness of 0.008 inches to 0.010 inches at the protrusion 165. Due to the scoring, the protrusion 165 can be lifted with a force of 5 to 75 pounds, such as a force between 15 and 40 pounds, and sheared from the base 162. In some cases, the diameter of the circular protrusion is 0.375 to 0.850 inches (e.g., 0.575 inches in diameter as seen in FIG. 10B). In some cases, the area of the protrusion 165 is 0.1 to 0.5 in 2 (e.g., 0.26 in as seen in FIGS. 10B - 10D) 2 ) and in some cases, the area of the base 162 is 2.0 to 5.0 in2 (e.g., 3.95 in as seen in FIGS. 10B - 10D 2 ). The area of the circular protrusion is a part of the total surface area of the base 162. In some cases, the diameter of the base 162 is 1.5 - 3.0 inches (e.g., 2.244 inches as seen in FIGS. 10B - 10D). In some cases, the area ratio of the circular protrusion 165 to the base 162 is 0.01 - 0.50 (e.g., 0.065 as seen in FIGS. 10B - 10D).

[0178] In some cases, when the protrusion is sheared off and removed, the protrusion and the corresponding opening have a surface area between 5% and 30% of the total pod end surface area. In some cases, the shape of the protrusion may be circular, may have a teardrop shape, a kidney shape, or any shape. In some cases, the protrusion may be round, but the serrated shape may be circular, have a teardrop shape, a kidney shape, or any shape.

[0179] FIG. 10A shows a cap 166 having a first opening 222 and a second opening 224. The first opening substantially matches the shape of the opening 164. When the protrusion 165 is removed, the first opening 164 is exposed and extends through the base 162. The second opening 224 has a shape that matches two overlapping circles. One of the overlapping circles has a shape that matches the shape of the protrusion 165, and the other of the overlapping circles is slightly smaller. The ramp 226 extends between the outer edges of the two overlapping circles. There is an additional material thickness of 0.010 to 0.100 inches (e.g., 0.070 inches) at the upper part of the ramp transition. This extra height helps to lift, rupture, and open the opening of the protrusion during rotation of the cap, as will be described in more detail with reference to FIGS. 11A - 11G.

[0180] Figures 11A and 11B show the cap 166 initially attached to the base 162, with the protrusion 165 aligned with the larger of the overlapping circles of the second opening 224 and extending through the larger of the overlapping circles. When the machine's processor 122 activates the electric motor 146 to rotate the gear 168 and the annular member 161, the rotation of the cap 166 slides the lamp 226 under the lip of the protrusion 165, as shown in Figures 11C and 11D. The continuous rotation of the cap 166 applies a lifting force that separates the protrusion 165 from the rest of the base 162 (see Figures 11E through 11G), and then aligns the first opening 222 of the cap 166 with the opening 164 of the base 162, resulting in the removal of the protrusion 165. The electric motor 146 can apply a torque of up to 1,000 ozf inches to lift and shear the protrusion 165. In some machines, the process of removing the protrusion also removes any product (frozen or unfrozen) that may accumulate in the recess at the end of the protrusion.

[0181] In some machines, the motor 124 decelerates during the protrusion shearing process and then accelerates during the dispensing process. In this case, it is advantageous for the drive shaft to rotate without stopping or reversing the mixing cycle, the shearing cycle, and the dispensing cycle in order to reduce the likelihood of stalling the motor 124.

[0182] Some pods include a structure for holding the protrusion 165 after the protrusion 165 is separated from the base 162. In pod 150, the protrusion 165 has a head 167, a stem 169, and a foot 171 (best seen in FIG. 11G). The stem 169 extends between the head 167 and the foot 171 and has a cross-section smaller than that of the head 167 and the foot 171. When the rotation of the cap 166 separates the protrusion 165 from the rest of the base 162, the cap 166 pushes laterally against the step 169, and the head 167 and the foot 171 gather the cap 166 together along one edge of the overlapping circles of the second opening 224. This configuration holds the protrusion 165 when the protrusion 165 is separated from the base 162. Such a configuration reduces the likelihood that the protrusion will fall into the standby receptacle when the protrusion 165 is removed from the base. After the mixing paddle 160 of the machine rotates and distributes the frozen confection through the opening 224, the motor 124 rotates the cap 166 to close the opening 224 so that any residual product (e.g., ice cream) does not leak out of the pod during melting.

[0183] Some pods include other means for separating the protrusion 165 from the rest of the base 162. For example, in some pods, the base has a removable cutting mechanism riveted to the base. The rotatable cutting mechanism has a shape similar to the shape described for the cap 166, but this secondary part is riveted to the outer periphery of the base 162 and is located within the outer periphery rather than being attached over and around the base 162. When the refrigeration cycle is complete, the processor 122 of the machine activates the arm of the machine to rotate the riveted cutting mechanism around the rivet. During rotation, the cutting mechanism engages, cuts, and removes the protrusion 165, leaving the opening 164 of the base 162 in place.

[0184] In another example, some pods have a cap with a sliding knife that moves across the base to remove the protrusion. The sliding knife is actuated by the machine and, when triggered by the controller, slides across the base to separate, remove, and collect the protrusion 165. The cap 166 has a guillotine function that can slide straight across and over the base 162 when actuated by the machine. The cap 166 engages, cuts, and removes the protrusion 165. In another embodiment, this guillotine function may be at the center of the machine rather than at the cap 166 of the pod 150. In another embodiment, this guillotine function can be attached as a secondary part within the base 162 rather than as a secondary attached part as in the case of the cap 166.

[0185] Some pods have a dispensing mechanism that includes a pop-top that can be engaged and released by the machine. When the refrigeration cycle is complete, the machine's arm engages and lifts the tab of the pod, thereby pushing, piercing the base, and creating an opening in the base. The chilled or frozen product is dispensed through the opening. The pierced surface of the base remains adhered to the base and is held inside the pod during dispensing. Mixing either avoids the pierced surface or rotates on the pierced surface, or in another embodiment, allows the mixing paddle to continue rotating unobstructed. In some pop-tops, the machine's arm separates the pierced surface from the base.

[0186] FIG. 12 is an enlarged schematic side view of the pod 150. The mixing paddle 160 includes a central stem 228 and two blades 230 extending from the central stem 228. The blades 230 are helical blades shaped to stir the contents of the pod 150 and remove material adhering to the inner surface of the body 158 of the pod 150. Some mixing paddles have a single blade and some mixing paddles have more than two mixing paddles.

[0187] A fluid (e.g., a liquid material, air, or a frozen confection) flows through the openings 232 in the blade 230 as the mixing paddle 160 rotates. These openings reduce the force required to rotate the mixing paddle 160. This reduction can be significant as the viscosity of the material increases (e.g., as ice cream is formed). Also, the openings 232 assist in mixing and aerating the material within the pod. In some machines, the openings 232 represent approximately 36.5% of the total surface area of the mixing paddle 160.

[0188] The side - edge of the blade 230 in the lateral direction defines a slot 234. The slot 234 is offset such that as the mixing paddle 160 rotates, material adhering to the inner surface of the body 158 is removed by one of the blades 230 from most of the inner surface of the body 158. The mixing paddle is wider than the first end 210 of the body 158 of the pod 150 by 160, but the slot 234 is an alternating slot that facilitates the insertion of the mixing paddle 160 into the body 158 of the pod 150 by rotating the mixing paddle 160 during insertion so that the slot 234 is aligned with the first end 210. In another embodiment, the outer diameter of the mixing paddle is less than the diameter of the opening of the pod 150, allowing for continuous (non - rotating) insertion into the pod 150. In another embodiment, one blade of the mixing paddle has an outer diameter wider than the second blade diameter and thus allows for continuous (non - rotating) insertion into the pod 150. In this mixing paddle configuration, one blade is intended to remove (e.g., scrape off) material from the sidewall, while the second blade of shorter diameter is intended to perform more agitating operations.

[0189] Some mixing paddles have one or more blades hinged to a central stem. During insertion, the blades may be hinged in a compressed configuration and released to a deployed configuration upon insertion. Some hinged blades open and lock while rotating in a first direction and are foldable when rotated in a second direction opposite the first direction. Some hinged blades lock in an outward position once in the pod, regardless of the direction of rotation. Some hinged blades are manually condensed, expanded, and locked.

[0190] The mixing paddle 160 rotates clockwise (when observed from above the machine) to remove the accumulation of frozen confections from the wall of the pod 214. Gravity forces the confections removed from the wall of the pod to fall towards the first end 210. In the counterclockwise direction, the mixing paddle 160 rotates to lift the material and agitate it towards the second end 212. When the paddle changes direction and rotates clockwise, the material is pushed towards the first end 210. The protrusion 165 of the base 162, when removed as shown and described with respect to FIG. 11D, causes the clockwise rotation of the mixing paddle to dispense the produced food and drink from the pod 150 through the opening 164. Some paddles mix and dispense the contents of the pod by rotating in a first direction. Some paddles mix by moving in a first direction and dispense by moving in a second direction when the pod is opened. Some mixing paddles do not reverse direction.

[0191] The central stem 228 defines a recess 236 sized to receive the drive shaft 126 of the machine 100. The recess and the drive shaft 126 have a square or cut cross-section such that the drive shaft 126 and the mixing paddle 160 are rotationally constrained. When a motor rotates the drive shaft 126, the drive shaft rotates the mixing paddle 160. In some embodiments, the cross-section of the drive shaft is of a different shape and the cross-section of the recess is a conforming shape. In some cases, the drive shaft and the recess are threadedly connected. In some pods, the recess includes a fitting structure that grips the drive shaft and rotationally couples the drive shaft to the paddle.

[0192] Figures 13A - 13D show a body 1300 that is substantially similar to the body of the pod 150 or the can 158. However, the body 1300 has two joined ends 1302, 1304 instead of the domed end of the body 158 of the pod 150. By eliminating the domed end, the body 1300 is easier to manufacture using methods such as punching, extrusion, or rolling. As shown in the isometric view of Figure 13D, the body 1300 resembles a hollow tube and includes a thin-walled extrusion 1306. A malleable material such as aluminum can be used to form the body 1300. Each of the joined ends 1302, 1304 engages a corresponding lip of the lid 1308 and is joined to each other using a joining machine. Figure 13B shows a cross-section of the second joined end 1304. Figure 13C shows the joining process between the body 1300 and the lid 1308. In some cases, the joining connection of the body 1300 to the lid 1308 is similar to the seam seen in Figure 35C. In this way, the lid 1308 is attached to each end of the aluminum pod 1300.

[0193] One of the lids 1308 includes a grommet at its center (not shown) to rotationally couple a mixing motor to a mixing paddle within the body 1300 (not shown) and to seal the pod in its initial configuration. The grommet is overmolded, affixed, or clamped to the lid 1308. The body 1300, together with the two lids 1308, defines the pod.

[0194] In these systems and methods, sterilization is typically performed before freezing the liquid ice cream mix.

[0195] Figure 14A is a photograph of a retort machine, and Figure 14B is a photograph of the retort sterilization chamber inside the retort machine. As described above, the retort machine is used to sterilize and enable the pod to be stored at room temperature. To help reduce factory operations by the processes described herein, single-serve pods (cans) can be filled with a liquid ice cream mix that has not been pasteurized and not homogenized. Next, during the retort sterilization process, for example, using the retort machine shown in the images of Figures 14A and 14B, the pod can be rocked back and forth at various speeds, such as 180 cycles per minute at 3 Hz. During the retort process, the liquid ice cream is sloshed (i.e., homogenized) inside the pod while being simultaneously exposed to high temperature and high pressure for sterilization.

[0196] By using a dairy product that has not been pasteurized in our pod and performing the retort process with the pod before use, the dairy product inside the pod is pasteurized only once. This is in contrast to the typical pasteurization process shown in Figure 1 where dairy products are usually pasteurized before leaving the dairy factory. That is, the dairy product is pasteurized twice, for example, once at the dairy factory and once in our retort process.

[0197] Because the liquid sloshes in the can inside the retort container, the sloshing of the liquid ice cream in the pod can significantly increase the heat transfer at 250°F for between 2 and 15 minutes. Both the can and the retort container are pressurized. For example, this pressure may be 100 psi. By pasteurizing through the retort during homogenization, this method eliminates the steps of conventional operations for making ice cream (e.g., the process of FIG. 1), which improves efficiency and reduces costs. This process can provide a more authentic and fresh taste, as well as a more appealing food with better color, texture, and mouthfeel. The recent growth in the premium category indicates strong consumer demand for enhanced food quality.

[0198] The retort agitation of these pods during and in retort sterilization produces a much higher quality low-acid food for ambient storage. Also, it can reduce the cycle time by about 90% and the energy consumption by up to 50% compared to the conventional batch static retort process. This rapid retort process reaches the F0 lethality value earlier, reducing over-cooked notes and loss of ice cream flavor, as well as reducing discoloration associated with the retort process of many static agitation retorts or slow agitation retorts. Also, the process can homogenize the liquid mix. Homogenizing the liquid mix by rapid agitation is advantageous because the two operations of sterilization and homogenization of the liquid ice cream mix are achieved at once. FIGS. 14A - 14B are photos of a retort sterilization chamber that includes dozens or hundreds of pods that can be moved back and forth at 3 Hz or up to 180 cycles per minute to minimize caramelization by accelerating heat transfer and simultaneously homogenizing the liquid ice cream mix while retort cooking dairy products.

[0199] During this pasteurization process that can be carried out using a retort process, the pasteurized dairy product may caramelize and turn brown, which may not be desirable. The highest rate of browning, or more generally called color development, may be caused by the presence of fructose that begins to caramelize at 230°F.

[0200] Even though retorting at a higher temperature is generally preferred because it would allow the pasteurization process to be completed in less time, some of these systems and processes use a retort process that retorts at 250°F. When the retort is completed at 250°F, the effect of browning can be limited when fructose is removed from the ice cream mix formulation. Completing the retort at 250°F can limit the effect of browning when removing fructose from the ice cream mix formulation.

[0201] Since the caramelization process of fructose starts at 230°F, the highest rate of color development may be caused by fructose. Caramelization should not be confused with the Maillard reaction in which reducing sugars react with amino acids. The process of browning, i.e., the Maillard reaction, produces flavor and changes the color of the food. The Maillard reaction generally begins to occur at temperatures above 285°F. For at least these reasons, our retort temperature does not exceed 250°F, which would be preferred otherwise since the sterilization process would be faster.

[0202] For example, the caramelization temperature of fructose may be 230°F, galactose may be 320°F, glucose may be 320°F, lactose may be 397°F, and sucrose may be 320°F. In some examples, corn syrup, i.e., high fructose corn syrup (HFCS), forms hydroxymethylfurfural from the decomposition of fructose when heated to about 113°F.

[0203] Some of these systems use pods that contain clean label, milk, or sugar cream. Sometimes gum stabilizers are used, and preferably acacia gum, gellan gum, pectin, and cellulose gum, which have retort stability, can be used. Since lactose is a disaccharide, it may not be preferred in retort. Lactose is composed of subunits of galactose and glucose and may constitute about 2 to 8% of milk.

[0204] FIG. 15 is a flowchart of a method 250 implemented in a processor 122 for operating a machine 100. The method 250 is described with reference to the refrigeration system 109 and the machine 100. Also, the method 250 may be used with other refrigeration systems and machines. The method 250 is described as producing a single serving of ice cream, but can also be used to produce cooled or frozen drinks and foods.

[0205] The first step of the method is to turn on the machine 100 (step 260) and turn on the fans associated with the compressor 186 and the condenser 180 (step 262). The refrigeration system 109 then idles at a regulated temperature (step 264). In the method 250, the evaporator 108 temperature is controlled to remain at about 0.75 °C, but may vary by ±0.25 °C. Some machines operate at other idle temperatures, for example, from 0.75 °C to room temperature (22.0 °C). If the evaporator temperature is less than 0.5 °C, the processor 122 opens the bypass valve 190 to increase the heat of the system (step 266). When the evaporator temperature exceeds 1 °C, the bypass valve 190 is closed to cool the evaporator (step 268). From the idle state, the machine 100 may be operated to produce ice cream (step 270) or may be stopped (272).

[0206] After the pod is inserted, the user presses the start button. When the user presses the start button, the bypass valve 190 closes, the evaporator 108 moves to its closed position, and the motor 124 is turned on (step 274). In some machines, the evaporator is electronically closed using a motor. In some machines, the evaporator is mechanically closed, for example, by the lid moving from the open position to the closed position. In some systems, a sensor confirms that the pod 150 is present in the evaporator 108 before these procedures are taken.

[0207] Some systems include radio frequency identification (RFID) tags, or other intelligent barcodes such as UPC barcodes or QR codes. The identification information regarding the pod can be used to trigger specific cooling and mixing algorithms for a particular pod. These systems can optionally read the RFID, QR code, or barcode and identify a mixing motor speed profile and a mixing motor torque threshold (step 273).

[0208] Also, the identification information can be used to facilitate direct-to-consumer sales (e.g., via the Internet or using a subscription model). This approach and system described herein enable the sale of ice cream via e-commerce because the pods can be stored at room temperature. In a subscription model, the customer pays a monthly fee for a predetermined number of pods that are shipped to the consumer each month. The consumer can select personalized pods from various categories (e.g., ice cream, healthy smoothies, iced coffee, or frozen cocktails) and personalized flavors (e.g., chocolate or vanilla). In some cases, the machine itself can be rented using a subscription model. In some cases, reusable pods and mixing paddles can also be rented.

[0209] Also, identification can be used to track each pod in use. In some systems, the machine can be linked to a network and configured to inform the vendor which pods are in use and which need to be replaced (e.g., through weekly shipments). This method is more efficient than having consumers go to the grocery store to purchase pods.

[0210] These operations cool the pod 150 within the evaporator 108 while rotating the mixing paddle 160. As ice cream forms, the viscosity of the contents of the pod 150 increases. The torque sensor of the machine 100 measures the torque of the motor 124 required to rotate the mixing paddle 160 within the pod 150. When the torque of the motor 124 measured by the torque sensor meets a predetermined threshold, the machine 100 moves to the dispensing mode (step 276). The dispensing port opens and the motor 124 reverses direction (step 278) to extrude the frozen confection from within the pod 150. However, in some machines, the motor 124 does not reverse direction. The mixing paddle 160 rotates slowly to allow frozen material to form on the walls of the pod 150 while the evaporator 108 cools. As the rate of frozen material formation on the pod walls accelerates due to the temperature decrease, the RPM of the mixing paddle 160 increases.

[0211] As described above, in some machines, the rotational speed of the mixing paddle 160 accelerates to help air enter the frozen confection to achieve improved overrun (preferably at least 30% overrun) and provide sufficient speed to extrude the ice cream from the outlet port of the pod 150 while achieving a consistent stream of ice cream coming out of the pod.

[0212] Accelerating the rotational speed of the mixing paddle 160 increases the current required. The following table shows the current of a current prototype machine used to drive the mixing paddle 160 as a function of RPM and the time to the freezing process (which affects the viscosity of the ice cream).

Table 4

[0213] The rotation of the mixing paddle 160 lasts for about 1 to 10 seconds to distribute the contents of the pod 150 (step 280). The machine 100 then switches to the defrost mode (step 282). Frost accumulating on the evaporator 108 can reduce the heat transfer efficiency of the evaporator 108. Further, the evaporator 108 can freeze up to the pod 150, both the first portion 128 and the second portion 130 of the evaporator can freeze, and / or the pod can freeze up to the evaporator. The evaporator can defrost between cycles to avoid these problems by opening the bypass valve 190, opening the evaporator 108, and turning off the motor 124 (step 282). The machine then diverts gas through the bypass valve for about 1 to 10 seconds to defrost the evaporator (step 284). The machine is programmed to defrost after each cycle unless the thermocouple reports that the evaporator 108 is already above the freezing point. The pod can then be removed. The machine 100 then returns to the idle mode (step 264). In some machines, a thermometer measures the temperature of the contents of the pod 150 and determines when to distribute the contents of the pod. In some machines, the dispensing mode starts when a predetermined time is achieved. In some machines, a combination of the torque required to rotate the mixing paddle, the temperature of the pod, and / or the time determines when to distribute the contents of the pod.

[0214] When the idle time expires, the machine 100 automatically shuts off (step 272). Also, the user can turn off the machine 100 by pressing and holding the power button (286). When turning off, the processor opens the bypass valve 190 to equalize the pressure across the valve (step 288). The machine 100 waits for 10 seconds (step 290) and then turns off the compressor 186 and the fan (step 292). The machine then turns off.

[0215] Figures 16A - 16C are detailed flowcharts of an alternative method 1250 implemented in the processor 122 to operate the machine 100. Method 1250 is similar to method 250. Method 1250 can be used with the refrigeration systems and machines described herein. Method 1250 is described as producing soft - serve, but can also be used to produce other cooled or refrigerated beverages and foods.

[0216] The first step of method 1250 is to plug the machine 100 into an outlet (step 1252). Once an electrical connection is detected, the processor 122 can initialize all variables. The processor 122 and network hardware can search for software updates via WiFi or using a wired Ethernet connection (step 1254). In some cases, cellular service (such as 4G / 5G LTE) is included in the machine 100 and can be used for connections for software updates as well as to push notifications and alerts to user devices. Step 1252 occurs once an electrical connection is detected and does not necessarily require the machine 100 to be turned on.

[0217] To verify the proper functioning of the machine 100 before use, when this electrical connection is detected, a startup routine is executed (step 1256). This process can identify problems or malfunctions within the machine and verify that the machine 100 is ready for use. The processor 122 locks the lid and proceeds to verify that the lid locking mechanism is functioning properly. This can be verified using sensors including, but not limited to, limit switches, hall sensors, potentiometers, or any sensor capable of monitoring the position of the lid and the function of the locking mechanism. During this time, sensors within the machine 100 verify that the mixing motor is rotating properly. Also, sensors within the machine verify that the rivet shearing mechanism is in the home position, and if not, the rivet shearing mechanism is moved to the home position so that the pod can be properly inserted into the machine. Also, sensors within the machine 100 verify that the penetration motor is in the home position, and if not, the penetration motor is moved to the home position (i.e., the retracted position) to avoid premature penetration of the pod.

[0218] The evaporator within the machine 100 is guaranteed to be in the closed position, which can be monitored using the current sent to the motor that closes the evaporator. When the evaporator is open, the current applied to the motor is low, while when the evaporator is closed, the current applied to the motor is high. This difference in current is used to monitor the closure of the evaporator. A predetermined current is used as the threshold to monitor when the evaporator is open compared to when it is closed. The machine 100 is configured to wait for the evaporator to close before proceeding. Also, sensors within the machine verify that the evaporator is in the open position when the machine is turned on (step 1258).

[0219] The machine 100 then waits for the evaporator to open, the penetration motor to retract (if not already done), and the rivet motor to return home (if not already done). The lid is also unlocked (step 1260). The machine 100 then turns off or enters a low-power standby state until the machine is turned on (step 1262).

[0220] When the power button of machine 100 is pressed, the light of the power button turns on (step 1264). The machine user interface part includes a single button with an LED ring. The single button functions as a power-on button, a start button, and a power-off button. On some machines, multiple buttons can be used. For example, separate buttons are used for the power and the ice cream manufacturing process. At this point, the processor 122 instructs the compressor and the fan to turn on. Also, the temperature of the inlet port to the evaporator is adjusted by the processor 122 to be about 33 - 40°F via a bypass valve.

[0221] When a pod (e.g., pod 150) is inserted into the machine and the lid is closed (step 1265), the processor 122 of machine 100 reads the identification on the pod (step 1266). The identification is read in various ways such as barcodes, RFID tags, UPC bars, QR codes, or using the identification methods described above. If no code is detected, then machine 100 returns to step 1264 to allow the lid to be opened and closed again. Also, the machine may send an alert to a display or a user device to notify that the pod was not properly identified. An audible alert may also be used. When the lid is closed again, the identification of the pod is tried again. When the pod is properly identified by the processor 122 and a barcode is detected, machine 100 proceeds to step 1268 where the processor 122 controls the button light to blink as a notification to the user that the pod has been identified and that machine 100 is ready for use. Also, the processor 122 may send an alert of this notification to a display or a user device. An audible alert may also be used.

[0222] When the lid opens, machine 100 returns to step 1264, resets machine 100, and repeats the pod identification process (step 266).

[0223] If the power button is held down or a predetermined time has elapsed without interaction with the user, for example, the process times out, and then the processor 122 of the machine 100 proceeds to open the bypass valve to initiate the shutdown process (step 1270). The bypass valve is opened immediately before shutdown to quickly equalize the pressure between the high-pressure and low-pressure sides of the refrigeration system. This reduces the startup load on the compressor if the compressor is restarted immediately after being turned off. The processor 122 then proceeds to turn off the compressor and the fan after waiting for about 5 seconds (step 1272), and the machine 100 is turned off (step 1262), and the machine 100 enters the low-pressure standby state.

[0224] Figure 16B is a continuation of method 1250. When the start button is pressed, the processor 122 proceeds to update the refrigeration parameters based on the information contained regarding the pod (step 1274). In some cases, the information can identify the temperature, number of times, brand, flavor, contents of the pod, and mechanical aspects of the pod such as, for example, the pressure of the pod, the type of pod used, the dimensions of the pod, the design aspects of the mixing paddle, or the design aspects of the rivet shear. The data usage of the pod or data regarding the pod and / or the machine can be transmitted to the server using the processor 122 via WiFi or using the cellular network connection described above. This data can be used when identifying the customer or order frequency of the pod subscription service. Also, the lid of the machine 100 is locked in the closed position at this point, so the user cannot accidentally open the lid during operation of the machine. The bypass valve machine is also turned off.

[0225] The evaporator is closed to grip the pod (step 1276). As described above, a predetermined target current can be used by the processor 122 to identify the proper closed position of the evaporator. Also, the evaporator can be used to align the longitudinal axis of the pod with the longitudinal axis of the evaporator to ensure that the pod is centered in the evaporator. The evaporator must be closed before the piercing motor pierces the can, thus ensuring that the can is centered before it is pierced.

[0226] The piercing motor is here controlled by the processor 122 to lower the dagger into the pod (step 1278). As described herein, in some pods, the dagger penetrates the pod and then the dagger is rotationally engaged with the mixing paddle. In some pods, the dagger need not penetrate the pod.

[0227] When the mixing motor is rotationally engaged with the pod, the mixing motor is then controlled to be turned on by the processor (step 1280). Sensors on the machine 150 and connected to the processor 122 can ensure that the mixing motor is operating properly and that no malfunction is detected. The processor 122 commands the rotational speed of the mixing motor to gradually accelerate (increase) (step 1282). At this point, the processor 122 controls the mixing motor that rotates the mixing paddle inside the pod. The machine 100 is now in the process of freezing the ice cream and the processor 122 waits for this process to complete before proceeding. As described above, the information can be determined from the information from the pod via the barcode. The information may be related to the freezing process, such as motor torque, which may be a proxy for measuring the viscosity and freezing time of the ice cream. The machine 100 waits until the processor 122 detects that the ice cream is in a proper state for dispensing.

[0228] When the preparation for dispensing the ice cream is complete, the user is notified by the processor 122 using the display on the machine 100, or an audible alert. In some cases, the processor 122 controls the power button light to blink three times, although any number of blinks or lighting patterns can be used to distinguish this state of the ice cream manufacturing process from the power-off or power-on state. The rivet motor of the rivet shear mechanism is then signaled by the processor 122 to be rotating.

[0229] Figure 16C is a continuation of method 1250. When the rivet mechanism engages the pod's rivet, the current of the motor increases dramatically. This increase in current can be used by the processor 122 to monitor and detect when the rivet shear mechanism actually engages the pod's rivet during the shearing process. As the rotation of the rivet motor continues, the rivet shear mechanism causes the pod's rivet to be removed from the pod (e.g., the rivet can be mechanically sheared). In some machines, the rivet or protrusion is moved out of the way instead of being sheared or removed (e.g., in a reusable pod, it may be advantageous to have a reusable rivet). The processor 122 of the machine 100 ensures that a spike in current to the rivet motor occurs before the continuation. The absence of current may indicate a malfunction of the machine 100.

[0230] After the rivet is sheared, the processor 122 controls the rivet shearing mechanism to rotate a certain distance to align the hole in the cutting cap attached to the pod with the port in the pod. This alignment is required to distribute the contents of the pod. The rivet is sheared to prevent the auger from freezing to the pod, so the ice cream base is mixed. To prevent the ice cream from being discharged from the pod while the rivet is being sheared, the rivet needs to be sheared and rotated 250° quickly, for example, in less than 2 seconds (step 1286). When the processor 122 of the machine 100 senses that the rivet has been removed, the rivet motor can be turned off (step 1288).

[0231] Ice cream is dispensed from the machine here. It is common for the mixing motor to experience an increase in torque / load / current demand after almost all of the ice cream has been dispensed from the pod. This increase in torque / load / current is caused because the evaporator is still actively cooling, but most of the mass has been discharged from the pod. As a result, the ice cream remaining in the pod becomes very cold and may freeze the mixing paddle to the pod. To mitigate this effect, the bypass valve is timed to slightly warm the pod after almost all of the ice cream has been dispensed, which typically represents a waiting time of a few seconds (500 ms) before opening the bypass valve, but this waiting time can be adjusted based on information about the pod and the configuration of the machine 100. Note that it may take several seconds for the evaporator to start warming air once the bypass valve is opened. Once this process is complete, after a waiting time of usually 10 ms, the bypass valve is closed (step 1292). The machine 100 then waits until all of the ice cream has been dispensed before proceeding (step 1294).

[0232] During the dispensing process, the speed of the mixing motor also increases (step 1295). The mixing motor is continued to rotate during the dispensing process, which may be about 4 to 12 seconds.

[0233] At this point, the machine 100 is ready to start the reset process (step 1296). First, the processor 122 spins down and commands the mixing motor to turn off. After the cooling cycle is complete and before the pod is removed, the pod is cooled in the evaporator down to just below freezing. At first glance, the evaporator inlet temperature is adjusted by the processor 122 via the bypass valve to about 25 - 30°F. This temperature is a necessary step before the bypass valve defrosts the evaporator from the pod to prevent liquid from leaking out of the pod and before the evaporator is opened and the pod is removed.

[0234] The processor 122 further commands the rivet motor to the home position and commands the penetration motor to retract. The process waits until one or more sensors detect that the rivet motor is in the home position and the penetration motor is in the retracted position.

[0235] The processor 122 of the machine 100 commands the lid to unlock so that the user can lift the lid and expose the top of the pod (step 1297). At this point, the processor 122 adjusts the evaporator inlet temperature to about 33 - 40°F via the bypass valve (step 1298). The processor 122 can wait until the evaporator outlet temperature reaches at least 32°F before proceeding.

[0236] At this point, the processor 122 commands the evaporator to open so that the pod is released from the grip of the evaporator in anticipation of removal of the pod 150 from the receptacle of the machine 100. Also, the processor 122 may allow the evaporator to remain open for a predetermined time during this process (step 1209). The pod 150 is then removed from the machine 100 (step 1293).

[0237] The machine then returns to step 364 where the processor 122 of the machine 100 configures the machine 100 to be ready for the next pod to be inserted (as seen in FIG. 16A).

[0238] Figures 17A - 17D are perspective views of machine 300. Machine 300 is substantially similar to machine 100 but has different mechanisms for opening lid 112 to insert pod 150 and for connecting the drive shaft of machine 300 to pod 150.

[0239] Figure 17A shows machine 300 with lid 112 in its closed position. In this position, handle 302 is in the same plane as lid 112. Figure 17B shows handle 302 lifted to an intermediate position. In this position, lid 112 still covers evaporator 108, but drive shaft 126 is slightly lifted as will be described in more detail with respect to FIGS. 18A and 18B.

[0240] The auxiliary cover 115 of machine 300 slides back into housing 104 rather than pivoting like the auxiliary cover 115 of machine 100. Figure 17C shows that as handle 302 is further lifted, handle 302 lifts lid 112 to the open position and auxiliary cover 115 begins to slide back under housing 104. Figure 17D shows that auxiliary cover 115 has completely retracted into the housing, leaving space for handle 302 and lid 112 to swing far enough rearward to insert pod 150 into evaporator 108.

[0241] Figures 18A and 18B are partial cross - sectional views of machine 300 showing the insertion of drive shaft 304 into the interior region of evaporator 108. Drive shaft 304 is attached to handle 302. As shown in FIG. 18A, drive shaft 304 is close to but spaced from pod 150 when handle 302 is in its intermediate position. Moving the handle to its closed position forces drive shaft 304 to engage the internal mixing paddle through the second end of pod 150.

[0242] Figure 19 is a partial cutaway perspective view of drive shaft 304. The drive shaft 304 includes teeth 306, a lock section 308, and a flange 310. When the movement of the handle 302 to its closed position forces the drive shaft 304 through the second end 212 of the pod 150, the teeth 306 cut through the second end of the pod 150 (see Figure 9C). In some systems, a sharp edge without teeth is used.

[0243] The lock section 308 is received in a hole within the mixing paddle 160. The hole within the mixing paddle 160 and the lock section 308 of the drive shaft 304 have mating shapes such that rotation of the drive shaft 304 causes rotation of the mixing paddle 160. The drive shaft 304 has a lock section 308 with a square cross-section. Some drive shafts have lock sections with other shapes (e.g., hexagonal or octagonal cross-sections). The flange 310 of the drive shaft 304 is attached to the handle 302. A central hole 312 extends through the drive shaft 304. When the drive shaft 304 is inserted into the pod 150, the central hole 312 of the drive shaft 304 allows air to flow into the pod 150 as the cooled food or drink is mixed and discharged / distributed from the other end of the pod 150. Some drive shafts are made of a hard material.

[0244] In some machines, the drive shaft 304 is configured such that the through end / tip of the drive shaft 304 has a wider diameter than the central portion of the drive shaft 304, and thus the hole made in the aluminum pod is wider than the diameter of the central portion of the drive shaft 304. This configuration reduces the likelihood that the central portion of the drive shaft touches the pod during rotation. Further, the drive shaft 304 may be covered with a self-cleaning and / or hydrophobic coating that reduces the amount of pod material that adheres to the drive shaft 304. In some machines, the drive shaft 304 is released so that it does not hit the second end 212 of the pod 150 during the piercing process.

[0245] Figure 20 is a perspective view of the dispenser 153 of the machine 30. The protrusion 163 of the annular member 161 is more rectangular in shape than dovetail-shaped. The dispenser 153 is otherwise substantially the same as the dispenser 153 of the machine 100.

[0246] Some machines implement other approaches to the pod-machine joint than the machine 100. For example, some machines have a pod-machine joint that is movable relative to the body of the machine to expose a receptacle defined by the evaporator. The loading system can control the position of the pod-machine joint relative to the body of the machine. In some of these machines, the lid is fixed in place relative to the body of the machine.

[0247] Figures 21A - 21C show a wedge system 400 associated with a pod-machine joint 350 that uses a lid 402 to fasten an evaporator 352 around a pod 354. Figures 21A and 21B are a schematic perspective view and a schematic side view, respectively, of the pod-machine joint 350 with the lid 402 spaced apart from the evaporator. Figure 21C is a schematic side view of the pod-machine joint 350 engaging the lid 402 in a closed position.

[0248] Each side of the evaporator 352 has a manifold 404 that connects channels inside the wall of the evaporator 352 to an inlet port 368 and an outlet port 369. The manifold 404 has an inclined portion 406 near the inlet port 368 and the outlet port 369. The lid 402 has a wedge 408 on the side facing the evaporator 352. The wedge 408 has a flat surface 410 and an inclined surface 412. When the pod-machine joint 350 engages the lid 402 (e.g., by movement of the lid towards a fixed-position evaporator or by movement of the evaporator towards a fixed-position lid), the wedge 408 on the lid 402 contacts the inclined portion 406 of the manifold 404. The movement applies a force to the inclined portion 406 of the manifold 404 on the evaporator, clamping the first and second portions of the evaporator 352 that are closed around the pod 354 for a snug fit. When the closed lid 402 is locked, the snug fit is maintained.

[0249] The loading mechanism described above receives the pod by inserting the pod into the receptacle from above the pod-machine joint. Some machines load the pod from the bottom of the pod-machine joint.

[0250] Figures 22A - 22C show a drive shaft 540 having a drive lug end 542 for engaging complementary recesses 544 within a mixing paddle 546. The drive lug end of the drive shaft rotatably couples the drive shaft 540 to the mixing paddle. A drive shaft having a drive lug end 542 can penetrate the pod more easily than a drive shaft having a square end.

[0251] FIG. 23 shows a perspective view of a machine 550 that is substantially similar to the machine 300 shown in FIGS. 17A - 17D. However, machine 550 has a handle 552 connected to a pinion 554 for moving a drive shaft up and down. Handle 552 is triangular in shape and extends from a first end 556 to a second end 558. A recess 560 on the first end 556 of handle 552 provides a gripping surface. Recess 560 indicates to the user where to grip handle 552. Some handles have other shapes (e.g., rectangular, square, or circular). Some handles are shaped like the handle shown in FIG. 17A (e.g., handle 302). A recess 562 extends from a second portion 558 of the handle into handle 552. Pinion 554 and elevator shaft 564 are disposed in recess 562. The user rotates handle 552 about the second end 558 to lift the first end 556 of handle 552 to open the lid 112. The user rotates handle 552 about the second end 558 and pushes the first end 556 of handle 552 downward to close the lid 112.

[0252] Figures 24A - 24E show a machine 600 having a handle 555 that operates similarly to the handle 302 on the machine 300 of FIGS. 17A - 17D. However, in FIGS. 24A - 24E, the handle 555 and the lid 112 rotate about the same hinge. The handle 555 is larger and enables the user to use the entire hand to apply force to the drive shaft through the handle. The length of the handle 555 increases the mechanical advantage provided by the handle 555 and reduces the amount of force required by the user to pierce the pod and engage the drive shaft 304. Also, the pod 150 shown in FIG. 24B includes a centering head 580 that engages the mixing paddle 160. The centering head 580 holds the mixing paddle 160 in place along the axis of rotation of the central stem 228. FIGS. 24A and 24B show the handle 555 and the lid 112 in its closed position. The drive shaft 304 passes through the pod 150 and extends into the evaporator to engage the mixing paddle 160. FIGS. 24C and 24D show the handle 555 in the open position and the lid 112 in the closed position. The drive shaft 304 is retracted and held within the lid 112. FIG. 24E shows the lid 112 and the handle 555 in the open position. The evaporator 108 is exposed and the pod 150 can be inserted into the evaporator 108.

[0253] Figures 25A - 25C show a machine 650 having a spring - loaded handle 575 that is substantially similar to the handle 555. The spring - loaded handle is shown attached to the machine 650 in the closed position in the plan view of FIG. 25A. The spring 576 provides a smooth transition of the handle 575 when the drive shaft 304 is extended into the evaporator to pierce the pod 150 and engage the mixing paddle 160. The spring 576 is connected to the bearing housing 577 and the handle 575 (most clearly seen in FIG. 25C). The cover 585 extends over a second spring 579 (most clearly seen in FIG. 25C), and the force of the second spring 579 can facilitate raising / lowering the handle 575 on the machine 560. An auxiliary cover 583 that is substantially similar to the auxiliary cover 115 is shown in the retracted position.

[0254] FIG. 25B is a perspective view of the handle 575 attached to the machine 650 in the closed position. The auxiliary cover 583 is shown in the closed position. A pair of deflectors 581 and 582 engage the cover 585 of the handle 575. The pair of deflectors 581 and 582 are attached to the auxiliary cover 583.

[0255] FIG. 25C is a partial cutaway view showing a cross-section of the handle 575. The positioning pin 578 sets the position of the spring 276. The positioning pin is connected to the bearing housing 577. As the handle 575 is lifted, the angle of the bearing changes, helping the bearing to slide back and forth without binding during lifting and closing. The spring 276 assists in keeping the bearing on the track. A second spring 579 is located at the rear of the bearing housing 577 to further provide a smooth transition of the handle 575. The handle 575 is connected to the cover 585 by a mechanical fastener such as a bolt (not shown).

[0256] FIGS. 26A - 27B show a machine 700 having a sliding lid assembly 701. Such a sliding lid assembly 701 can reduce the overall height of the machine 700 compared to a machine having a lid assembly that opens upward. This approach allows the machine 700 to be more compact and fit on a kitchen counter under a dish rack.

[0257] The machine 700 is substantially similar to the above-described machine (e.g., machine 650). However, the sliding lid assembly 701 slides along tracks, namely rails 707 and 708, to move from a closed configuration 705 (shown in FIGS. 26A and 26B) to an open configuration 706 (shown in FIG. 26C). In the open configuration 706, the sliding lid assembly 701 translates rearward along the linear rails 707 and 708, sliding the cover 702 to reveal an opening 710 within the machine 700 for accessing the pod 150. The user typically pushes / pulls the handle 715 to translate the sliding lid assembly 701 from the closed configuration 705 to the open configuration 706.

[0258] Figures 27A and 27B show platform 714 of a machine 700 that includes a motor (not shown but disposed under plate 716 for driving pulley 712 and belt 711) for driving a paddle, and a solenoid 713 for driving a drive shaft / plunger downward into pod 150. Pulley 712 attached to the drive shaft of the motor, and the motor are attached to plate 716. Since the motor is mechanically connected to the sliding lid assembly 701, the motor also translates as the sliding lid assembly 701 translates from the closed configuration 705 to the open configuration 706. The motor is rotationally coupled to the paddle through pulley 712 and belt 711. Belt 711 is under tension both when the lid is in its open position and when the lid is in its closed position. However, other drive mechanisms such as a gear system can also be used. Also, belt 711 translates with the sliding lid assembly 701, and a belt tensioning system can also be used (not shown). When the sliding lid assembly 701 is in the closed configuration 705 and ready for use, solenoid 713 engages the drive shaft and drives the drive shaft downward into pod 150 (not shown). The drive shaft / plunger / dagger projects out from the domed end of pod 150 and engages the hexagonal cavity of the mixing paddle (such as mixing paddle 160) of pod 150 (these details are described above and not shown in Figures 27A and 27B). The drive shaft is rotationally coupled to belt 711 so that the motor can rotationally drive the drive shaft when the drive shaft is joined to the paddle within pod 150 (not shown).

[0259] Figures 28A - 28D show a machine 650 that is substantially similar to the machine described above (e.g., machine 600). However, in machine 650, solenoid 713 is not used to actuate the drive shaft / plunger / dagger and engage pod 150. Instead, motor 705 is connected to drive shaft 755 using a rack 752 and pinion 751 system to translate the drive shaft along the axis between a disengaged configuration 760 and an engaged configuration 761. Motor 750 is oriented perpendicular to drive shaft 755. Drive shaft 755 is substantially similar to the drive shaft described above, except for the following differences. A set of bearings 753 and 754 allows drive shaft 755 to rotate about central axis 756. Drive shaft 755 is rotationally coupled to a mixing motor (not shown) using belt 757. Belt 757 rotates pulley 767 which is press fit (usually press fit) to intermediate member 766. The hexagonal hole 770 in intermediate member 766 allows a keyed connection with the hexagonal section 769 of drive shaft 755. This keyed connection mechanically couples the rotation of pulley 767 to drive shaft 755 such that drive shaft 755 is constrained from pivoting with respect to pulley 767. Intermediate member 766 is rotationally connected to bearings 768 that allow it to rotate freely with respect to frame 758 and frame 771.

[0260] The drive shaft 755 is axially fixed using a shoulder 762 that fits onto bearing 754 and a snap ring 759 that fits onto bearing 753. Bearings 753 and 754 are fixed within housing 763. Housing 763 translates axially between a free configuration 760 and an engaged configuration 761 using a rack 752 and pinion 751 system that axially couples motor 750 to housing 763. Housing 763 translates axially within a hole 765 of frame 758. A hybrid motor (not shown) rotates drive shaft 755 via belt 757 and motor 750, which is smaller and less powerful than normal, and translates drive shaft 755 axially via the rack 752 and pinion 751 system. Motor 750 is attached to housing 763 via motor mount 764.

[0261] In contrast to previous machines, machine 650 does not require the user to manually operate a handle to drill a hole through a pod into the drive shaft (dagger). In machine 650, this operation is controlled by motor 750 and is automatically controlled by machine 650. This provides an advantage when it is difficult for the user to manually operate a handle to apply the required penetration force. In some machines, an on-board controller uses an encoder (not shown) and limit switches (not shown) on motor 750 to monitor the axial position of drive shaft 755. For example, when the user inserts a pod (such as pod 150) and presses the start button, the evaporator closes and drive shaft 755 plunges into pod 150, potentially moving in small increments or rotating to ensure proper alignment with the paddle auger head, and mixing and refrigeration will begin.

[0262] Figure 29A shows a cross-section of a side view of an alternative drive shaft (dagger / plunger) assembly 800. The drive shaft assembly 800 is designed such that the drive shaft 806 is lowered and penetrates the pod only by the operation of a hybrid motor (not shown) passing through the pulley 801. Reversal of the rotation of the hybrid motor, and thus the pulley 801, fully retracts the drive shaft 806.

[0263] The drive shaft assembly 800 uses a hybrid motor (not shown) to drive the pulley 801. The pulley 801 rotates and engages with a first sprag bearing 802. The first sprag bearing 802 is a one-way rotating bearing, i.e., a ratchet system, that allows (i) the inner diameter of the bearing to rotate relative to the outer diameter of the bearing in a first rotational direction and (ii) the inner diameter of the bearing to be rotationally locked relative to the outer diameter of the bearing in the opposite rotational direction. The first sprag bearing 802 is connected to an intermediate component 803, such that when the first sprag bearing 802 rotates in the first rotational direction, the intermediate component 803 is rotationally locked to the pulley 801 and slips in the other direction. The intermediate component 803 is connected to a second sprag bearing 804. The second sprag bearing 804 is oriented opposite to the first sprag bearing 802 such that the second sprag bearing 804 is rotationally locked when the first sprag bearing 802 slips, and vice versa. The second sprag bearing 804 is connected to the housing 805. Thus, when the hybrid motor is rotated in one direction (i.e., clockwise 821 with respect to an observer looking in the direction 820), the intermediate component 803 rotates with the pulley 801. Otherwise (i.e., counterclockwise or opposite to the clockwise direction 821), the intermediate component 803 is fixed to the housing 805.

[0264] The drive shaft 806 has a left-handed thread cut for substantially its entire length. The thread engages with an internal female thread in the hole of the pulley 801 at the threaded joint portion 812. A detent pin, spring detent pin, or spring detent 807 is normally disposed at the upper portion of the drive shaft 806 via a press fit. When the hybrid motor begins to rotate 821 revolutions clockwise, the pulley 801 rotates and the drive shaft 806 also begins to rotate. The spring detent 807 of the drive shaft 806 rotates within the groove 811 (best seen in FIG. 29B) of the housing 805 until the spring detent 807 engages one of the protrusions 808 or 809 of the housing 805 at the joint portion 810. The joint portion 810 prevents further rotation of the drive shaft 806. A further 821 clockwise rotation of the pulley 801 causes the drive shaft 806 to translate and begin to screw into the pulley 801 at the threaded joint portion 812. The screwing continues until the spring detent 807 engages the recess 813 of the intermediate part 803 (best seen in FIG. 29D) and further engages the shoulder 815. The first and second sprag bearings 802, 804 are configured such that the intermediate part 803 rotates with the pulley 801 during the operating phase. At this point, the spring detent 807, and thus the drive shaft 806, begin to rotate 821 revolutions clockwise with the pulley. The dagger 814 of the drive shaft 806 is fully lowered here to penetrate the pod.

[0265] Upon reversal of the rotation of the hybrid motor, i.e., in the counterclockwise direction 822, the drive shaft 806 automatically retracts (i.e., no other motor or actuation method is required). During the retraction phase, the intermediate part 803 is fixed to the pulley 801 by the first and second S-plug bearings 802, 804. When the rotation is reversed, the spring detent 807 disengages from the shoulder 815 of the recess 813 of the intermediate part 803 and rotates 822 revolutions counterclockwise. The recess 813 retracts the spring detent 807 with a small shoulder 816.

[0266] Figure 30 shows a spring return stop 807 that engages a small shoulder 816. At this point, further counterclockwise rotation 822 of the pulley 801 causes the drive shaft 806 to begin screwing into the housing 805 from within the hole of the pulley 801 and into the groove 811. Further counterclockwise rotation 822 continues to unscrew the drive shaft 806 from the pulley 801, causing a reset of the drive shaft assembly 800. The drive shaft assembly 800 is reset here (fully retracted) and can be used again.

[0267] Clockwise rotation 821 of the pulley 801 engages the drive shaft 806, and counterclockwise rotation 822 disengages the pulley 801 within this machine, although some machines have a mirror version of the drive shaft assembly 800 where counterclockwise rotation engages the drive shaft and clockwise rotation disengages the drive shaft.

[0268] Figure 31 is a cross-sectional perspective view of a machine 900 that is substantially similar to a previous machine except for the evaporator assembly. In machine 900, the evaporator 902 is attached to a frame 903 and connected to a motor 901 that controls the opening and closing of the evaporator 902. The motor 901 is directly attached to the frame 903, allowing for an in-line connection between the motor 901 and the opening / closing operation of the evaporator 902. The motor system can provide a compact system with reduced mechanical complexity.

[0269] Figures 32A and 32B respectively show a perspective view and a partial cutaway perspective view of the evaporator assembly shown in Figure 31. The evaporator 902 is biased in the open position by a spring 905. When the motor 901 is energized, the motor 901 drives a nut 911 over a bolt 910 via a screw connection. This screwing operation reduces the space between the left bracket 908 and the right bracket 909 (left and right as observed with respect to Figures 32A and 32B). The torque of the motor 901 is transmitted to the nut 911 using a coupler 907. The coupler 907 is sized to mate with the nut 911 via a hexagonal hole. The torque of the motor 901 compresses the spring 905 and crushes the closed evaporator 902. Bolts 904 and 906 provide a hard limit to the closing operation so that the pods present within the evaporator are not crushed (the pods are not shown within the evaporator 902). Upon reaching the final closed position and providing this hard limit, the ends of each respective bolt 904 and 906 engage the right bracket 909. When the motor is reversed, the spring 905 expands and assists the evaporator 902 in opening to release the pods.

[0270] Figure 33A is a schematic view of a refrigeration system 930 that is substantially similar to the refrigeration system 109. The refrigeration system includes a condenser 180, a suction line heat exchanger 182, an expansion device 184, and a compressor 186. High-pressure liquid refrigerant flows from the condenser 180 to the evaporator 108 through the suction line heat exchanger 182 and the expansion device 184. The expansion device 184 restricts the flow of the liquid refrigerant fluid and reduces the pressure of the liquid refrigerant as it exits the expansion device 184. The low-pressure liquid then moves to the evaporator 108 where heat is absorbed from pods (such as pod 150) and the contents within the evaporator 108 change from liquid to gas. The vapor-phase refrigerant flows from the evaporator 108 to the compressor 186 through the suction line heat exchanger 182. In the suction line heat exchanger 182, the cold vapor leaving the evaporator 108 precools the liquid leaving the condenser 180. The refrigerant enters the compressor 186 as a low-pressure gas and leaves the compressor 186 as a high-pressure gas. The gas then flows to the condenser 180 where heat exchange cools the refrigerant and condenses it to a liquid.

[0271] The second bypass conduit 190 enables the application of warm gas to the evaporator 108 to defrost the evaporator 108. Also, a first bypass conduit 188 that directly connects the discharge of the compressor 186 to the inlet of the compressor 186 can be used, but is not shown. The first and second bypass conduits 188, 190 can be made effective and ineffective using valves (such as solenoid valves or throttle valves - not shown).

[0272] Consumers expect high-quality frozen confections in the first cycle without waiting several minutes for the machine to warm up. A refrigeration system (e.g., refrigeration system 109) having a capillary tube heat exchanger 182 is not actively controlled and may take longer to reach a steady state than an actively controlled system (e.g., a system using a thermal expansion device or valve). When the machine is initially turned on, the warming process enters a "hot gas bypass mode" that circulates the solenoid to control the evaporator 108 temperature lower than the ambient state.

[0273] Compared to the hot gas bypass mode, the risk of starting the machine in the standard cooling mode is that if there is no pod or heat load in the evaporator, the refrigerant may not be completely vaporized before returning to the compressor 186, and there is a risk of damaging the compressor by attempting to compress the incompressible liquid. Another limitation of the hot gas bypass technique is that after a few minutes the system warms up somewhat, but it is not the actual temperature the system will experience under cooling conditions. Further, during the bypass mode, the capillary tube orifice 182 receives a constantly changing flow rate, which is different from the flow rate during the cooling mode.

[0274] The pod (e.g., pod 150) is inserted into the evaporator 108, and when the cooling process is started, the temperature and refrigerant flow rate require time to adjust from the hot gas bypass mode state to the cooling state. This delay extends the time to cool the product compared to when the pod is placed in the evaporator in the cooling mode. However, it enables starting the refrigeration process in the cooling mode without the risk of heat load damaging the compressor.

[0275] The refrigeration system 930 directly transitions to the cooling mode as a solution to the delay that requires time for the temperature and refrigerant flow rate to adjust from the hot gas bypass mode state to the cooling state. An electric heater 931 located either before or after the evaporator 108 provides a heat load at startup to simulate the cooling of ice cream. The heater vaporizes the refrigerant, similar to how the liquid ice cream mix in the pod affects the refrigerant system 930, enabling the refrigerant system 930 to achieve a steady-state cooling condition with respect to refrigerant temperature, pressure, and flow rate without the need for an ice cream pod placed within the machine. The machine reaches a steady state faster than the refrigeration system 109 from startup at ambient (room) temperature, without risking damage to the compressor. Although not shown in FIG. 33A, the first bypass line 188 or bypass valve (seen in FIG. 6) can also be used in the refrigeration system 930.

[0276] FIG. 33B shows a refrigeration system 940 that uses a thermoelectric cell 941. The thermoelectric cell 941 provides a heat "capacitance" or "container" to remove a certain amount of cooling load from the compression system, thereby shortening the refrigeration time. When the machine starts up from room temperature, valves 942 and 943 (e.g., solenoid valves or throttle valves) are open and the thermoelectric cell 941 does not receive refrigerant. Towards the end of or at the end of the first cooling cycle, valve 943 closes and cold refrigerant flows into the thermoelectric cell 941. When cold refrigerant flows into the thermoelectric cell 941, the paraffin inside the thermoelectric cell 941 solidifies. Pre-cooling the thermoelectric cell at the end of one cycle enables the thermoelectric cell 941 to be used to reduce the cooling load on the compressor 186 during the next cooling cycle. The energy required to solidify the material is large compared to the energy required to lower its temperature.

[0277] In thermoelectric cell 941, wax is used. Many waxes solidify at convenient temperatures for use in thermoelectric cell 941. Some waxes (e.g., alkanes) have melting points in the range of 5°C to 10°C. For example, dodecane wax or tridecane wax has a melting point in this range. These waxes are used in thermoelectric cell 941 because they solidify at a temperature between the hot side temperature and the cold side temperature of refrigeration system 940, store heat "capacitance", and can transfer or use that capacitance during subsequent cooling cycles. Energy is removed from the wax during times when the machine is not in the cooling mode or at least when the user does not expect the machine to be cooling. Cooling the thermoelectric cell 941 has the additional advantage of heating the refrigerant that protects the compressor 186 from liquid refrigerant that would cause damage to the compressor 186. During the second cooling cycle, valve 942 is closed and high temperature liquid refrigerant that pre-cools the thermoelectric cell 941 is sent to the thermoelectric cell 941 before the refrigerant reaches the expansion device 184. During the same cycle, valve 943 is open to allow the cold refrigerant to bypass the battery. At the end of the second cycle, valve 943 is closed and valve 942 is opened to cool the thermoelectric cell 941 for the next cycle. This process is repeated, allowing the cooling from the end of one cycle to be used or "stored" for use in the next cycle, which can shorten the required refrigeration time.

[0278] Figures 34A - 34D show a mixing paddle that is substantially similar to mixing paddle 160, except that the mixing paddle is partially overmolded with polymer to remove frozen ice cream from inside the pod (e.g., pod 150). In Figure 34A, an aluminum paddle 951 is formed (usually punched, bent / twisted, but can also be formed by other methods such as casting, forging, or machining). Ribs 960 on the upper region 952 of the aluminum paddle 951 provide special rigidity to the thin regions of the aluminum paddle 951. The thin regions of the aluminum paddle 951 receive large torque from the drive head during the mixing process, and this special rigidity is important as it reduces the deformation of the aluminum paddle 951 under this applied torque. Edge molds 958 and 959 are formed in place (i.e., injected, cast) on each edge 954 and 955 respectively. This process is often called "overmolding" and can create one part with multiple materials.

[0279] Other molding techniques can be used, such as molding edge molds 958 and 959 separately and then inserting the aluminum paddle 951 or joining the aluminum paddle 951 to the edge molds 958 and 959. These overmolded parts 956 - 959 can help remove the accumulation of frozen ice cream from the inner diameter of the pod wall (e.g., pod wall 214) and the bottom of the pod (e.g., the first end 210). The silicone upper cap 956 can be molded in place on the upper region 952 of the aluminum paddle 951, and the silicone bottom cap 957 can be molded in place on the bottom region 953 of the aluminum paddle 951. The mixing paddle 950 is formed when the overmolding is complete. The upper cap 956 can be overmolded to also include the drive head 961 of the mixing paddle 950. Figures 34C and 34D are a top view and a bottom view of the mixing paddle 950 respectively.

[0280] In some cases, a plastic dip coating is used to cover the aluminum paddle 951 to prevent the metal mixing paddle 951 from rotating at the metal lid (e.g., the first end 210) and the pod wall (e.g., the pod wall 214). In some cases, a polyolefin coating is used. Typical properties of the polyolefin coating are shown in the following table.

Table 5

[0281] Also, FIGS. 35A - 35D show pairs of notches 962. The notches 962 are sized such that they fit into the lip 971 inside the second end of the pod (such as the first end of 150). Although shown on the mixing paddle 951, other mixing paddles (e.g., mixing paddle 950 or mixing paddle 160) can also include such notches. The contacts 972, when installed, enable the mixing paddle 951 to rotate along the lip or track 971 inside the pod 150, guiding the mixing paddle 951 and providing structural support to the mixing paddle 951.

[0282] FIGS. 36A and 36B show a mixing paddle 1550 that is substantially similar to the mixing paddle 951, except that the notch 1551 of the mixing paddle 1550 avoids direct contact with the lip 971 of the pod 150. The pod 150 includes a cap 166. The notch 1551 is sized to allow the use of a polymer liner 1552 or a bushing between the lip 971 of the pod 150 and the notch 1551 of the mixing paddle 1550. The polymer liner 1552 is used to reduce the friction between the notch 1551 and the lip 971.

[0283] The polymer liner 1552 is formed as a ring and functions as a bushing to reduce friction between the rotating mixing paddle 951 and the metal lip 971 of the pod 150. By reducing friction, wear and abrasion of the materials of the mixing paddle 971 and the lip 971 are reduced. Also, the polymer liner 1552 reduces the heat within the pod when the rotary mixing paddle rotates when making frozen confections within the machine. The polymer liner 1552 includes a receptacle that engages the lip 971. The polymer liner 1552 is radially restrained by the lip 971. The polymer liner 1550 includes a flat upper surface 1553 that contacts the lower surface of the notch 1551 of the mixing paddle 1550. The polymer liner 1550 includes a radially inner surface 1554 that contacts the radially outer surface of the notch 1551 of the mixing paddle 1550.

[0284] Figure 37A shows a cross-section of a perspective view of a pod's first end 981 - substantially similar to the first end 210 of pod 150, but including a formed-on connection for receiving a drive shaft. A silicone sealing grommet 980 is formed on top between the first end 981 and a plastic plug or paddle driver 982. The formed-on molding causes a covalent bond that creates an airtight seal between the grommet 980 and the paddle driver 982. A head 983 protrudes from the first end 981 for engagement with a drive shaft of a hybrid motor (not shown). The head is keyed to provide a rotational locking connection with the drive shaft. By providing a sealed connection, this approach avoids the need for the drive shaft to penetrate the pod and thus uses the gas (usually nitrogen) stored in the pod to assist in the generation of overrun or loft. In some cases, when the drive shaft rotates the paddle driver 982, the covalent bond between the hybrid paddle 950 and the grommet 980 breaks, allowing the shaft to rotate and air to flow into the pod to cause overrun. In another approach, the grommet 985 can be adhered to a plastic plug or paddle driver 986. Figure 37B shows the grommet 985 sliding over the shaft 987 and being adhered to a predetermined location on the paddle drive 986. Various other examples of grommets or sealing components such as the grommet 991 or lip seal 992 (or rotary seal) shown in Figures 37C and 37D respectively can be used.

[0285] Figures 38A - 38D are perspective views of the mixing paddle 1350 of the pod 150 having integral dog ears 1354, and the mating drive head 1352 that forms the mating drive assembly 1355. The assembly 1355 rotationally couples the ice cream machine's dagger / drive shaft to the mixing paddle 1350 and helps avoid unwanted deformation, buckling, or bending when the machine's torque is high. In the assembly 1355, the mixing paddle 1350 is punched or formed using sheet metal, and one or more dog ears 1354 are formed by bending the sheet metal over the ends of the mixing paddle 1350. The mixing paddle 135 is made from aluminum that is about 0.032 inches thick and is then bent using a sheet metal press / die / machine to form the dog ears 1354 on the mixing paddle 1350. The dog ears 1354 can provide the mixing paddle 1350 with increased rigidity and torsional rigidity compared to mechanical reinforcements such as ribs. Some mixing paddles include dog ears 1354 in addition to ribs.

[0286] To transmit torque, the inner surface 1360 of the dog ear 1354 aligns with the corresponding surface of the mating drive head 1352 seen in the translucent perspective view of FIG. 38A and seen in more detail in FIGS. 38C and 38D.

[0287] The mating drive head 1352 receives a dagger / drive shaft (not shown in FIGS. 38A - 38D) from the ice cream machine and rotationally couples the dagger / drive shaft to the mixing paddle. The mating drive head 1352 is typically constructed from aluminum, metal, or a rigid plastic.

[0288] As described above, the pod 150 is originally sealed. As the dagger / drive shaft is lowered into the domed region 1362 of the pod 150, the dagger / drive shaft penetrates the pod 150 and is received by the receptacle 1358 of the mating drive head 1352.

[0289] Referring to FIG. 38C, the fitting drive head 1352 can be slidably connected to the mixing paddle 1350 by friction fitting. By manufacturing the diameter or width of the fitting drive head 1352 such that there is a slightly larger gap between the inner surfaces 1360, 1364 of the corner fold 1354, a slight interference fit or friction fit can be achieved when assembling the fitting drive head 1352 to the mixing panel 1350. A detent or other latch can be incorporated into either the mixing paddle 1350 or the fitting drive head 1352 to hold the mixing paddle 1350 to the fitting drive head 1352 and ensure a proper rotational coupling. The fitting drive head 1352 can be fastened in place. Also, the fitting drive head 1352 can be releasably connected to the mixing paddle 1350.

[0290] The corner fold 1354 of the mixing paddle 1350 can be designed to allow for a one-way rotational coupling. For example, in FIGS. 38A - 38D, clockwise rotation of the drive shaft will be rotationally coupled to the mixing paddle 1350, while counterclockwise rotation will be released by the anti-symmetric design of the corner fold 1354.

[0291] During operation, the domed region 1362 of the pod 150 is penetrated, the dagger / drive shaft engages the receptacle 1358 of the fitting drive head 1352, and the drive shaft can rotate quickly to mix the ice cream, cause overrun, and dispense the ice cream.

[0292] Pod 150 can be normally filled and then retorted or filled aseptically. In either case, pod 150 is backfilled with nitrogen so that air does not enter the pod prematurely. This is commonly referred to as the "headspace." However, during the ice cream mixing process, it is desirable to introduce air into the mixing process to cause overrun. In some machines, the pod does not need to introduce air and can rely on the nitrogen in the pod. In these cases, the pod may remain sealed for at least part of the mixing process. In some cases, air can be introduced during the mixing process.

[0293] Figures 39A - 39B are perspective views of the mixing paddle 1350 of pod 150 that engages with the mating drive head 1370 to form the mating drive assembly 1365. The function of the mating drive head 1370 is similar to that of the mating drive head 1352 in that it rotationally couples the drive shaft of the machine to the mixing paddle 1350, but is different in that pod 150 is never penetrated by the drive shaft when the mating drive assembly 1365 is used.

[0294] The mating drive head 1370 includes a receptacle 1378 that receives the shaft 1382 of the grommet 1380 and rotationally couples the drive shaft 1374 to the mixing paddle 1350. The rotational connection and engagement between the mating drive head 1370 and the mixing paddle 1350 is similar to the connection (i.e., the rotational key connection) of the mating drive head 1352. Also, the mating drive head 1370 is connected, fastened, locked, or otherwise mechanically clamped in the same manner as the mating drive head 1352 using an interference fit (press fit).

[0295] The grommet 1380 includes a receptacle 1372 that may be similar to any of the drive shafts described herein, except that the drive shaft 1374 may be formed with a blunt end 1376 since the drive shaft 1374 need not penetrate the pod 150 at all. Instead, the hole in the domed portion of the pod 150 is made during filling and assembly of the pod, and the pod remains sealed during storage. The grommet 1380 includes an O-ring 1384 that is used to provide this sealed connection of the contents of the pod 150. Although only one O-ring 1384 is shown, multiple O-rings can also be used.

[0296] The male threads 1386 on the cylindrical outer surface of the grommet 1380 are configured to engage threadably with corresponding female threads 1388 of a seal member 1390. During installation, the grommet 1380 is installed from inside the pod 150, and the receptacle 1372 and male threads 1386 project from the pod 150. The seal member 1390 is screwed firmly onto the male threads 1386 of the grommet 1380 and also adhered to the surface of the domed portion of the pod 150. This forms an airtight seal between the pods 150 and allows the grommet 1380 to be rotated relative to the seal member 1390.

[0297] The seal member 1390 is fixed to the pod so that the pod cannot move. Fixing the seal member 1390 can be performed with an adhesive, a rivet, or any process that will hold the seal member 1390 in place. During operation, the drive shaft 1374 drops into the receptacle 1372 of the grommet 1380 and begins to rotate. When the drive shaft 1374 begins to rotate, the male thread 1386 begins to disengage from the female thread of the seal member 1390. Thereby, the grommet 1380 lowers itself into the pod 150. Due to this downward movement, the shaft 1382 of the grommet 1380 drops into the receptacle of the mating drive head 1370. The dimensions of the shaft 1382 and the receptacle 1378 can be made such that a rotational coupling occurs between the drive shaft 1374 and the mixing paddle 1350 only when the grommet 1380 is lowered into the pod 150 by the drive shaft 1374, or it can be made such that the grommet 1380 is always rotationally coupled.

[0298] When the grommet 1380 passes through the mating thread of the seal member 1390, the grommet 1380 can rotate freely without further vertical translation. For example, the cylindrical surface 1392 of the grommet 1380 will be able to rotate freely within the threads of the seal member 1390. That is, the drive shaft 1374 can continue to rotate to rotationally engage the long mixing paddle 1350 after the grommet 1380 has moved downward and has completely disengaged itself from the seal member 1390. The shaft 1382 of the grommet slides further into the receptacle 1378, and the shaft 1382 can be configured to be in the lowest position in the receptacle 1378 to maximize the strength of the rotational connection between the grommet 1380 and the mating drive head 1370.

[0299] Also, grommet 1380 can be configured to break the seal of pod 150 when caused to descend into pod 150 by rotation. When the seal is broken, air can enter the pod 150 to assist in the mixing of the ice cream and the generation of overrun. The dimensions of the screw engagement 1386 and the shafts 1374, 1382 and the receptacles 1372, 1378 can be made to sizes that minimize or maximize air intake during the mixing process. For example, if no air is desired at all, pod 150 may remain sealed by using a very small thread pitch on grommet 1380, or a rotating seal may be used to completely eliminate the thread pitch. In this way, drive shaft 1374 can rotate indefinitely and the seal will not be broken. In other cases where maximum air intake is desired as quickly as possible, grommet 1380 may have a very large thread pitch such that the seal is broken in less than one rotation of drive shaft 1374.

[0300] Another advantage of the fitting drive assembly 1365 is that drive shaft 1374 never enters the pod 150. That is, drive shaft 1374 is not contaminated by the dairy product and thus does not require cleaning. Further, since the pod 150 does not need to be penetrated, the possibility of aluminum fragments entering the can is significantly reduced or eliminated.

[0301] Grommet 1380 is typically constructed from aluminum, metal, or a hard plastic so that it can withstand the torque required during the ice cream manufacturing process. Also, a hard durometer elastomer that would help seal the pod 150 could be used. The seal member 1390 can also be made from these materials and the O-ring 1384 is typically an elastomer.

[0302] Figures 40A - 40C are plan and perspective views of the mixing paddle 1350 of the pod 150 for forming the engagement drive assembly 1600. The engagement drive assembly 1600 is substantially similar to the engagement drive assembly 1365 seen in FIGS. 39A - 39B, except that the functions of the grommet 1380 and the engagement drive head 1370 are combined in a single component. This single component is the engagement drive head 1602.

[0303] The mixing paddle 1350 is rotationally coupled to the engagement drive head 1602 through a connection portion 1614 (seen best in FIG. 40C). The connection portion 1614 is preferably a welded connection, although other connections can also be used. In some cases, the connection portion 1614 is a friction connection formed by engaging one or more grooves 1616 of the engagement drive head 1602 with one or more complementary edges of the mixing paddle 1350. In some cases, the connection portion 1614 is engaged by rotating the engagement drive head 1602 90 degrees relative to the mixing paddle 1350. In some cases, the connection portion 1614 is formed during the manufacturing process when the engagement drive head 1602 is formed at the assembly position on the mixing paddle 1350 as shown in FIGS. 40A - 40C. In some cases, the connection portion 1614 is fixed (e.g., adhered). In some cases, the mechanical connection is made with a fastener (e.g., a set screw).

[0304] A seal member 1604, substantially similar to the seal member 1390, is fixed to the pod so that the pod cannot move. Fixing the seal member 1604 can be performed with an adhesive, a rivet, or any process that will hold the seal member 1604 in place. The seal member 1604 is shown on the outer surface of the pod 150, although in some pods, the seal member 1604 is inside the pod. In some pods, the seal member 1604 extends from the inside of the pod 150 to the outside of the pod 150.

[0305] The male thread 1606 on the cylindrical outer surface of the insert drive head 1602 is configured to engage threadably with the corresponding female thread 1608 of the seal member 1604. During operation, the drive shaft of the machine (not shown in FIGS. 40A - 40C) descends into the receptacle 1610 of the insert drive head 1602. The receptacle 1610 is keyed (best seen in FIG. 40B) so that rotation between the drive shaft and the insert drive head 1602 is coupled. When the drive shaft begins to rotate, the male thread 1606 begins to disengage from the female thread of the seal member 1604. Thereby, the insert drive head 1602 lowers itself into the pod 150. Due to this downward movement, the mixing paddle 1350 also descends into the pod 150, but the amount of descent is preferably small by using a small thread pitch for the threaded connection between the insert drive head 1602 and the seal member 1604. When the male thread 1606 of the insert drive head 1602 passes below the lower edge of the female thread 1608 of the seal member 1604, the threaded connection disengages and the insert drive head 1602 (and the mixing paddle 1350) can rotate freely within the pod 150, and the bottom of the mixing paddle 1350 descends onto the lip 971 of the pod 150 (not shown in FIGS. 40A - 40C). At this point during operation, the mixing paddle 1350 can rotate under the control of the mixing motor of the machine.

[0306] The threaded connection between the male thread 1606 and the female thread 1608 is reversible when the rotation of the mixing motor is reversed. Thereby, the machine can reseal the pod 150.

[0307] Also, the insert drive head 1602 includes a cylindrical section 1620 configured to center the insert drive head 1602 and the mixing paddle 1350 within the pod 150 after the threaded connection between the male thread 1606 and the female thread 1608 has disengaged. The outer diameter of the cylindrical section 1620 is slightly less than the inner diameter of the female thread 1608 such that rotational clearance is possible but it is also possible to center the mixing paddle 1350 within the pod 150.

[0308] Also, the mating drive head 1602 functions to seal the pod 150. Before the mating drive head 102 descends to the position shown in FIG. 40A, an O-ring (not shown in FIGS. 40A - 40C) located in the groove 1612 is pressed against the inner dome of the pod 150 to form a seal. This seal is complemented by the threaded connection between the male thread 1606 and the female thread 1608. These seals help to seal out external air from entering the pod 150 so that the pod 150 can remain sealed until it is ready for use in the machine.

[0309] FIGS. 41A - 41F are perspective views of the mixing paddle 1350 that engages with the mating drive head 1402 to form the mating drive assembly 1400. In the mating drive assembly 1400, the pod 150 is penetrated by the dagger / drive shaft 1406, but the dagger / drive shaft 1406 does not contact the contents of the pod 150, and any aluminum debris resulting from the penetration operation is trapped in the sealed space 1408 from the contents of the pod 150. When the dagger head 1410 slides into the receptacle 1412 of the mating drive head 1402, the dagger / drive shaft 1406 is rotationally coupled to the mixing paddle 1350. The rotational engagement between the mating drive head 1402 and the mixing paddle 1350 is similar to that of the mating drive heads 1352, 1370.

[0310] The guide bushing 1404 is fixed or adhered inside the domed region of the pod 150. The mating drive head 1402 includes a cylindrical protrusion 1416 that includes a recess for the O-ring 1414. The O-ring 1414 seals the mating drive head 1402 to the guide bushing 1404. The dagger / drive shaft 1406 passes through the domed region of the pod 150 and rotates the mating drive head 1402 and the mixing paddle 1350. The mating drive head 1402 rotates relative to the guide bushing 1404. The O-ring 1414 may be a dynamic O-ring. The protrusion 1416 of the mating drive head 1402 may be chamfered to provide a lead angle for facilitating the assembly of the mating drive head 1402 into the hole of the guide bushing 1404. The mating drive head 1402 or the guide bushing 1404 may be aluminum, metal, rigid plastic, or high durometer elastomer to support the torque required during the mixing, scraping, and dispensing of ice cream.

[0311] The mating drive assembly 1400 enables the pod 150 to be sealed during packaging. This seal remains intact even after being penetrated by the dagger / drive shaft 1406. That is, air does not enter the pod 150 during the mixing process, which is typically used to assist in the occurrence of overruns. However, in this case, the nitrogen in the pod can assist in the occurrence of overruns, and / or the micropores in the cylindrical protrusion 1416 can be used to allow air to enter the pod 150 for this purpose.

[0312] Figures 42A - 42D are perspective views of the mixing paddle 1350 that engages with the mating drive head 1420 to form the mating drive assembly 1425. The mating drive assembly 1425 is different from the mating drive assemblies 1355, 1365, 1400 in that only one part, namely the mating drive head 1420, is required to form a rotational coupling and a sealed connection.

[0313] The snap-fit drive head 1420 is molded from an elastomer or a rigid plastic and is configured to deform rotatably at the weakened region 1422 and break when torque is applied to the hexagonal surface 1424. The hexagonal surface 1424 is configured to engage slidably with a drive shaft of a machine (not shown). The large cylindrical bearing surface 1426 is configured to be fixed to the domed region of the pod 150 by adhesion or otherwise by permanent fastening.

[0314] The weakened region 1422 may be cylindrical. Also, the weakened region 1422 may be broken by the vertical displacement of the drive shaft to the hexagonal surface 1424, causing the entire central region of the snap-fit drive head 1420 to move downward. Sometimes, due to both vertical displacement and rotation, the weakened region 1422 may break.

[0315] Torque is transmitted from the snap-fit drive head 1420 to the mixing paddle 1350, similar to the snap-fit drive heads 1352, 1307, 1402. For example, the clockwise rotation of the snap-fit drive head 1420 causes a mechanical connection through compression at a location 1428 on the surface of the kink 1354 of the mixing paddle 1350 to transmit torque and rotationally couple the drive shaft of the machine to the mixing paddle 1350.

[0316] The snap-fit drive head 1420 is sealed during packaging, and the seal is configured to break during the ice cream mixing process, allowing air to enter the pod 150 and cause overrun.

[0317] Figures 43A through 43C show a mixing paddle 1000 having windows 1001 through 1004 that are offset (i.e., eccentric) from the center with respect to the drive shaft 1006. Windows 1001 and 1002 are cut such that the central sections 1007 and 1008 are radially deflected to alternate the sides of the mixing paddle 1000. Windows 1001 and 1002 need not alternate, but this configuration serves to rotate and balance. Windows 1001 and 1002 rock around the drive shaft 1006 and operate like mixing sticks, i.e., beaters, to help mix the frozen confection. Thus, the mixing paddle 1000 with windows 1001 and 1002 mixes the frozen confection better than a balanced windowed mixing paddle having a central portion that simply rotates at the center of the pod. Also, like the mixing paddles described above, the mixing paddle 1000 is helically shaped to push the frozen confection downward to facilitate top-to-bottom mixing and to push the frozen confection out of the pod. This pushing action is similar to a screw conveyor. The mixing paddle 1000 mixes the product in the lateral direction and draws air in to create loft. Further, the mixing paddle 1000 features one or more teeth 1004 that serve to crush the mixed product and scrape the product from the pod walls into smaller pieces or streams. This paddle has four teeth, but there is no upper limit to the number of teeth.

[0318] Some mixing paddles include ribs or other features to increase torsional resistance. Some mixing paddles exhibit high torsional stiffness (e.g., greater than 15 ozf-in) and high failure limit torque (e.g., greater than 150 ozf-in). Some mixing paddles have a low surface roughness (e.g., less than 8 - 16 Ra) to prevent product from adhering to the mixing paddle and to help remove product that adheres to the mixing paddle. When the mixing paddle has a surface roughness between 8 - 16 Ra, these machines discharge at least 85% and typically 95% of the frozen confection in the pod. Some mixing paddles have a recess at a second end of the mixing paddle to allow the mixing paddle to rotate about the central axis of the mixing paddle. During manufacture, the twist at the bottom of the mixing paddle can be very large, from 100° to 150°, which can be a problem for the stamping process that can tear the material of the mixing paddle. A cutout notch (not shown) at the center of the bottom of the mixing paddle blade allows the mixing paddle to be formed without tearing the material.

[0319] As described above, the cap 166 of the pod 150 includes a protrusion 165 that is sheared to allow for the dispensing of product from the pod (see, e.g., FIGS. 10A and 11A - 11G). The cap 166 is mounted on a base 162 and is rotatable about the outer periphery / axis of the pod 150. In use, when the product is ready to be dispensed from the pod 150, the dispenser 153 of the machine engages and rotates the cap 166 about the first end of the pod 150. The cap 166 rotates to an engaged position and then separates the protrusion 165 from the rest of the base 162. However, some systems incorporate the shear mechanism as part of the machine rather than as part of the pod.

[0320] Figures 44A - 44B show cross - sections of a perspective view of a machine 1100 having a protrusion shearing mechanism 1050 that engages a protrusion 165 and shears it from a base 162. The protrusion shearing mechanism 1050 does not require the cap to be rotationally aligned or oriented in any particular direction with respect to an evaporator 108 (not shown). For example, the pod 150 can be inserted into the evaporator without the user having to rotationally align the pod with the protrusion shearing mechanism 1050. The machine accepts the pod 150 at any angular orientation.

[0321] Figures 45A - 45E show a cam 1051 pivotally attached to a gear 1052 that is rotated by a shearing motor 1054. During operation, the cam 1051 rotates where the back side of the cam 1051 does not interfere as it moves along a home dog 157 (i.e., “home position”). When a pod 150 with a cap 166 is inserted into an opening 1059 of a frame 1053, a spring 1055 provides a force that presses the cam 1051 against the cap 166 of the pod 150. The frame 1053 is attached to a housing 1059 as part of the machine 1100 and is fixed in place.

[0322] As the gear 1052 rotates, the cam 1051 is brought into further contact with the cap 166, and a firm grip occurs as the cam 1051 is wedged between the rotating gear 1052 and the cap 166. The serrated surface 1056 of the cam 1051 provides this firm grip and helps prevent the cap 166 from rotating relative to the gear 1052. As the gear 1052 rotates, the cam 1051 moves from the home dog 1057 (i.e., “engagement position”). The rotation of the gear 1052 ultimately rotates the shearing cap, which shears the protrusion 165 and opens the pod opening.

[0323] Figure 46 is a cross - section of a perspective view of the machine 1100 showing the engagement of the cap 166 with the gear 1052. A bearing 1062 allows the gear 1052 to rotate with respect to the machine 1100, and a snap ring or retaining ring 1061 fixes the gear 1052 axially in place.

[0324] In some machines, the mixing paddle stops rotating during the shearing of the protrusion. In some machines, during the protrusion shearing process, the rotation of the cap 166 of the pod 150 is opposite to the direction of rotation of the mixing paddle 160. By rotating in the opposite direction, the possibility that the pod 150 slides within the evaporator 108 is reduced. This is shown in FIGS. 47A and 48B.

[0325] FIG. 47A shows a cap shearing system 1120 that is a sub-assembly of a machine. The cap shearing system 1120 features a protrusion shearing process that is performed clockwise 1110 (i.e., clockwise with respect to the viewing direction 1105 of the pod 150), and a mixing paddle 150 that rotates clockwise as well. In contrast, FIG. 47B shows a cap shearing system 1125 that enables the cap 166 to shear the protrusion 165 in a counterclockwise direction 1111 (counterclockwise with respect to the viewing direction 1105 of the pod 150). The cap 110 has a first opening 1102 and a second opening 1103 that reflect the first opening 222 and the second opening 224 of the cap 166.

[0326] By rotating the shearing cap 166 in the opposite direction of the mixing paddle 160, the rotational or torsional forces are canceled out, enabling the folding evaporator 108 to close with sufficient force to prevent the pod 150 from sliding / rotating within the folding evaporator 108. The first openings (222 and 1102) on the caps (166 and 1106) are important for proper alignment with the protrusion opening 165. If the pod 150 slides relative to the caps (166 and 1101), the first openings cannot be aligned, and the function of the machine is affected.

[0327] Some pods may include a first end that is removable, and a reusable mixing paddle may be inserted into the first end. The mixing paddle can be removed, cleaned, and reused for subsequent use.

[0328] Figs. 48A - 48C show a vending machine 1200 for selling various pods (e.g., pod 150), placing various pods inside a built - in machine (e.g., machine 600), manufacturing ice cream, and serving it into a bowl or a cone. In this way, vending machine 1200 may include various types of pods such as various types of ice cream, or any of the pods described above. One advantage is that vending machine 1200 can be used in commercial locations and can be easily used by more than one user. Further, since pod 150 does not need to be refrigerated before use, there is no need to refrigerate vending machine 1200, which reduces the operating and manufacturing costs.

[0329] As shown in Fig. 48A, vending machine 1200 includes nine pods arranged in a rectangular or square grid behind view window 1204 (one of which is named pod 150). Although nine pods are shown, any number of pods or arrangements can be used. Each of the nine pods can include a stack of pods behind the first pod such that when one pod is selected and removed from vending machine 1200, the pod behind it moves forward. This is usually caused by a driving element such as gravity and / or a spring. For example, pod 150 may have ten pods behind it so that the machine requires less frequent replenishment.

[0330] The vending machine 1200 includes an alphanumeric keypad 1206 that enables a user to make pod selections. For example, to select pod 1222, the user would enter "B" followed by "2" on keypad 1206. The vending machine 1200 also includes facilities for accepting money 1208 by using a cash receptacle and a coin receptacle respectively to receive cash and coins. The vending machine 1200 can also accept credit card payments or payments via an app or over the Internet using any method for transferring money from the user to the machine, such as using a credit card reader 1212 or Apple Pay. Also, a similar server or network used in machine 100 can be implemented in the vending machine 1200. For example, a subscription service can be used to enable a user access to a fixed number of pods each month.

[0331] As described above, the vending machine 1200 includes the functionality of the above-described cooling machine (e.g., machine 600). Machine 600 is shown with a dashed line to represent the fact that it is inside the vending machine 1200. Machine 600 includes an evaporator 1224 and a dispensing receptacle or opening 1216. Other features of machine 600 are not shown in FIGS. 48A - 48C, but it should be understood that the functionality of machine 600 is incorporated into the vending machine 1200 in a stand-alone package.

[0332] The vending machine 1200 includes a robotic arm 1214 (best seen in FIG. 48B) that can retrieve a pod based on a user's selection and place the pod in the evaporator 1224. To accomplish this, the robotic arm 1214 includes a basket or platform 1218 to receive the pod from the shelf and safely transport the pod to the evaporator 1224. The robotic arm 1214 is configured to move horizontally to move to the column of selected pods. The basket 1218 is configured to move vertically along the robotic arm 1214 to move to the column of selected pods. Both of these are typically driven by a belt drive system coupled to a rotary motor, although various operating methods can be used. Note that the robotic arm is shown in the retracted position in FIGS. 48A and 48C.

[0333] For example, when pod 1222 is selected, the basket 1218 moves to location "B2" as shown in FIG. 48B, and the pod 1222 is released into the basket 1218. When the pod enters the basket 1218, as described above, the pod behind the first pod can move to replace pod 1202. However, in FIG. 48, location "B2" is currently empty.

[0334] Referring to FIG. 48C, the basket 1218 moves the pod 1222 to the evaporator 1224, and the process of manufacturing ice cream can begin. At this point, the refrigeration system of the vending machine 1200 cools the liquid material in the pod 1222 to a desired temperature, usually between 17 and 26 degrees Fahrenheit. The vending machine 1200 inserts a drive shaft into the pod 1222 to prepare the ice cream and rotates the mixing paddle of the pod 1222 to push the ice cream downward. The vending machine 1200 can open the pod 1222 by shearing the protrusion. The mixing paddle can then extrude the cream from the pod 1222 into a bowl, plate, or cone 1220. When the process is complete, the pod 1222 is removed and can be recycled. The receptacle in the vending machine 1200 can be used to store the used pod until the used pod is recycled.

[0335] Alternatively, instead of using the robotic arm 1214, the vending machine 1200 can also allow for manual selection by opening a window (substantially similar to window 1204 but excluding the hinge or a sliding mechanism that allows it to swing or slide open), allowing the user to reach in, make a selection, and manually place the pod into the evaporator.

[0336] Figure 49 shows a comparison of the typical ice crystal sizes of ice cream purchased in a store (e.g., Haagan-Dazs ice cream) versus the same ice cream that has melted, been packaged in a pod, and is supplied using the machine described herein. The ice cream purchased in a store that has melted, been packaged in a pod, and is supplied using the machine described herein is considered "ColdSnap" ice cream. Figure 49 shows that ColdSnap Haagen-Dazs ice cream 1502 has a 40% reduction in average ice crystal size compared to Haagen-Dazs ice cream 1504 purchased in a store. Specifically, ColdSnap Haagen-Dazs ice cream 1502 has an average ice crystal size of 19.2 μm compared to ColdSnap Haagen-Dazs ice cream 1504 purchased in a store that has an average ice crystal size of 39.1 μm. Further, the standard deviation of the measured ice crystals of ColdSnap Haagen-Dazs ice cream 1506 is much more precise than the standard deviation of ColdSnap Haagen-Dazs ice cream 1508 purchased in a store.

[0337] The machine described herein accelerates the impeller RPM so that there is not enough time for the ice crystals to grow large, which means that the ice crystal size of the frozen ice cream is much smaller, thereby significantly improving the texture and smoothness of the ice cream.

[0338] The measured values of the ice cream shown in Figure 49 were analyzed using an optical microscope at 40x magnification housed in a thermally insulated glove box at a temperature of approximately -10°C. The samples were transferred to the glove box immediately after being frozen by the ice cream machine described herein. Samples of the ice cream were placed on microscope slides and a drop of a dispersion solution of 50% pentanol and 50% kerosene was added to assist in dispersing the ice crystals and improving the image quality. Images of the ice crystals were obtained using an optical microscope at 40x magnification.

[0339] During post - processing, the diameter of each ice crystal seen in the image was measured by tracking the boundaries of the ice crystals shown in the image. Measuring the boundaries of the ice crystals was performed using the Microsoft Paintbrush for Mac, leveraging the light crystal measurement macro of the Image Pro Plus software program. For each sample of ice cream analyzed, at least 300 ice crystals were measured by analysis, verifying that an appropriate statistical average of the ice crystal sizes was obtained.

[0340] Figures 50A - 50E are images of ice crystals recorded using an optical microscope at a magnification of 40 times (40x) for various ice creams. Figure 50A includes three examples of ice crystal images recorded to measure the ice crystal size of ColdSnap Sweet Cream1 ice cream. The scale of the image is represented by a scale bar 1510 that represents a length of 100μm. The scale bar is shown in each of the three images of Figure 50A. The ice crystals are represented by generally circular - shaped objects (objects 1512) in the image. There are many ice crystals seen in the image. The average diameter of the ice crystals is 21.7μm, which is smaller than those purchased at the store of this ice cream.

[0341] Figure 50B includes three examples of ice crystal images recorded to measure the ice crystal size of ColdSnap Sweet Cream2 ice cream. The average diameter of the ice crystals is even smaller than the ice crystals seen in Figure 50A and is 19.5μm, still less than those purchased at the store of this ice cream.

[0342] Figure 50C includes three examples of ice crystal images recorded to measure the ice crystal size of ColdSnap Blueberry chobani ice cream. The average diameter of the ice crystals is 21.2μm, but some ice crystals are larger, with a diameter of 76.9μm. However, on average, the ice crystal size is still 21.2μm, less than those purchased at the store of this ice cream.

[0343] Figure 50D includes three examples of photocrystals recorded to measure the ice crystal size of ColdSnap Haagen-Dazs ice cream as described with reference to Figure 49. The average ice crystal diameter is 19.1 μm, and the largest measured ice crystal was 38.2 μm, which is the lowest maximum ice crystal size of the ice crystal measurements shown in Figures 50A - 50E. This average ice crystal size is smaller than that purchased at the store for this ice cream shown in Figure 50E.

[0344] Figure 50E includes three examples of ice crystal images recorded to measure the ice crystal size of Haagen-Dazs ice cream purchased at the store, also described with reference to Figure 49. In particular, the average diameter is 31.9 μm, which is much larger than the 19.1 μm ColdSnap Haagen-Dazs result. All quantitative values (i.e., average ice crystal diameter, standard deviation, minimum ice crystal diameter, and maximum ice crystal diameter) are larger for the ice cream purchased at the store compared to those of ColdSnap.

[0345] These results are a strong indication that the ice cream produced using the machines described herein produces a much smoother ice cream than ice cream purchased at the store. The ice cream produced using the machines described herein was 27% smaller in ice crystal size compared to an average ice cream crystal size of 25 μm.

[0346] The following is a table of the ice crystal size measurements shown in Figures 49 and 50A - 50E.

Table 6

[0347] Figures 51A - 51E are histograms of the ice crystal size measurements. Figure 51A is a histogram of the ice crystal size distribution of ColdSnap sweet cream 1 showing the exact standard deviation (or spread) of the measurements for an average ice crystal diameter of 21.7 μm.

[0348] Figure 51B is a histogram of the ColdSnap Sweet Cream 2 ice crystal size distribution showing the exact standard deviation of the measured values for an average ice crystal diameter of 19.5 μm.

[0349] Figure 51C is a histogram of the ColdSnap Blueberry chobani ice crystal size distribution showing the exact standard deviation of the measured values for an average ice crystal diameter of 19.5 μm.

[0350] Figure 51D is a histogram of the ColdSnap Haagen-Dazs ice crystal size distribution showing the exacting standard deviation of the measured values for an average ice crystal diameter of 19.1 μm.

[0351] Figure 51E is a histogram of the store-bought Haagen-Dazs ice crystal size distribution showing a wider standard deviation of the measured values for an average ice crystal diameter of 31.9 μm. Note that the average ice crystal diameter of the store-bought ice cream is not only larger than that of ColdSnap, but the standard deviation is much larger.

[0352] As described above, the ice cream produced using the machines described herein has, on average, a much smaller ice crystal size and a much more exacting standard deviation of ice crystal size compared to that purchased in the store. This is important because the ice cream machines described herein produce a smoother ice cream that does not require refrigeration or freezing prior to use. That is, the ice cream used in these machines can be "clean label" and can simply contain milk, cream, sugar, and powdered milk and can be stored at room temperature for up to 9 months in a sterilized pod.

[0353] Several systems and methods have been described. Nevertheless, it is to be understood that various modifications can be made without departing from the spirit and scope of the present disclosure. For example, although the evaporator is generally shown as being in a vertical orientation during use, some machines have an evaporator that is horizontally oriented or oriented at an angle to gravity during use. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. A method for providing a single-serving frozen confection made within less than 5 minutes, wherein the frozen confection has a temperature between 17°F and 26°F together with ice crystals in the frozen confection, and an average diameter of the ice crystals in the frozen confection is 50 μm or less, and the method comprises: Inserting a pod into the recess to provide the single-serving frozen confection while a recess of a machine is in an open position, the pod containing a material for providing the single-serving frozen confection; Moving the recess from the open position to a closed position to bring a side wall of the pod into contact with a side wall of the recess; While the side wall of the recess is in contact with the side wall of the pod and the recess is in the closed position, Cooling the recess with a refrigeration system of the machine and transferring heat from the pod while connecting a motor of the machine to a mixing paddle inside the pod; Mechanically agitating the frozen confection into the remaining material in the pod, moving warmer material to a cooler inner diameter of the side wall of the pod in contact with the recess from the center of the pod to promote heat transfer, and rotating the mixing paddle inside the pod to remove an accumulation of the frozen confection from the inner diameter of the pod and disperse the frozen confection to the center of the pod, wherein rotating the mixing paddle comprises increasing a rotational speed of the mixing paddle from an initial mixing speed to a higher mixing speed exceeding 200 RPM while cooling the frozen confection; Drawing air into the pod by rotating the mixing paddle inside the pod while cooling the recess without using a pump; thereby producing the single-serving frozen confection from the material in the pod; While continuously rotating the mixing paddle inside the pod, draw air into one end of the pod and discharge the frozen confection from the other end of the pod, and distribute the single-serving frozen confection by rotating the mixing paddle inside the pod. A method comprising.

2. The method according to claim 1, wherein the average diameter of the ice crystals in the frozen confection is 30 μm or less.

3. The method according to claim 1, further comprising filling the pod with the material before the pod is inserted into the recess to provide the single-serving frozen confection.

4. The method according to claim 1, wherein the frozen confection is a low-acid food that does not contain an emulsifier and / or a stabilizer.

5. The method according to claim 1, wherein the pod is a reusable pod for multiple uses.

6. The method according to claim 1, wherein the pod has completed a retort sterilization process so that the low-acid material in the pod can be stored at room temperature.

7. The method according to claim 1, wherein the pod is filled and sealed aseptically so that the low-acid material in the pod can be stored at room temperature.

8. The method according to claim 1, wherein the mixing paddle is part of the machine.

9. The method according to claim 1, wherein the mixing paddle is rotated by the motor, and the rotation speed of the motor is controlled in response to the changing viscosity of the frozen confection in the pod.

10. The method according to claim 1, wherein the recess of the machine is defined by the evaporator of the machine.

11. The method according to claim 1, wherein the refrigeration system cools the pod with a compressor and uses a two-phase refrigerant fluid.

12. The method according to claim 11, wherein the compressor is a reciprocating compressor.

13. The method according to claim 11, wherein the compressor is a rotary compressor.

14. The method according to claim 11, wherein the compressor is a direct current (DC) compressor.

15. The DC compressor is (i) increasing displacement at the beginning of the refrigeration cooling cycle of the pod, (ii) decelerating at the end of the refrigeration cooling cycle of the pod and has a variable motor speed configured to be so, the method according to claim 14.

16. The method according to claim 14, wherein the DC compressor has a variable motor speed configured to be adjusted according to the load applied to the refrigeration cycle of the machine.

17. The method according to claim 1, wherein the rotational speed of the mixing paddle is changed from 100 RPM to 1200 RPM while freezing the frozen confectionery.

18. The method according to claim 1, wherein the higher mixing speed is 800 RPM.

19. The method according to claim 18, further comprising continuously rotating the mixing paddle at the higher mixing speed while dispensing the frozen confectionery.

20. Increasing the rotational speed of the mixing paddle from the initial mixing speed to the higher mixing speed comprises increasing the rotational speed of the mixing paddle at a rate between 40 RPM and 242 RPM per 15 seconds while freezing the frozen confectionery, the method according to claim 1.

21. The method according to claim 1, wherein the higher mixing speed is 1000 RPM.

22. The method according to claim 1, wherein the initial mixing speed is 275 RPM.

23. The method according to claim 1, wherein the initial mixing speed is 50 RPM.

24. The method according to claim 1, further comprising warming the recess while dispensing the frozen confection.

25. The method according to claim 24, wherein warming the recess is started after starting dispensing of the frozen confection.

26. The method according to claim 24, wherein warming the recess is performed using a bypass valve of the refrigeration system.

27. The method according to claim 1, wherein dispensing the frozen confection occurs over 4 to 12 seconds.

28. Drawing air into the pod by rotating the mixing paddle inside the pod while cooling the recess creates air bubbles in the frozen confection, according to the method of claim 1.

29. Drawing air into the pod by rotating the mixing paddle inside the pod while cooling the recess results in at least 30% overrun of the frozen confection, according to the method of claim 1.

30. The method further comprises providing a sealed pod containing a liquid material, inserting the pod into the recess comprises inserting the sealed pod into the recess, and the method further comprises opening the sealed pod after inserting the sealed pod into the recess, according to the method of claim 1.

31. Opening the sealed pod comprises opening one end of the sealed pod and opening the other end of the sealed pod, according to the method of claim 30. The method according to claim 1, further comprising increasing a rotational speed of the mixing paddle inside the pod while dispensing the single-serving frozen confection from the pod. Claim 33 A method for providing a single-serving frozen confection, the method comprising: inserting a pod into a recess of a machine to provide the single-serving frozen confection while the recess of the machine is in an open position, the pod containing a material for providing the single-serving frozen confection; moving the recess from the open position to a closed position to bring a side wall of the pod into contact with a side wall of the recess; while the side wall of the recess is in contact with the side wall of the pod and the recess is in the closed position, cooling the recess with a refrigeration system of the machine and transferring heat from the pod while connecting a motor of the machine to a mixing paddle inside the pod; increasing a rotational speed of the mixing paddle from an initial mixing speed to a higher mixing speed of more than 200 RPM during a refrigeration cycle to remove an accumulation of the frozen confection from an inner diameter of the pod; mechanically agitating the frozen confection into the remaining material in the pod and dispersing the frozen confection toward a center of the pod while moving warmer material toward a cooler inner diameter of the side wall of the pod in contact with the recess from the center of the pod to promote more rapid heat transfer; drawing air into the pod by rotating the mixing paddle inside the pod while cooling the recess without using a pump; thereby producing the single-serving frozen confection from the material in the pod; dispensing the single-serving frozen confection by rotating the mixing paddle inside the pod to draw air into one end of the pod and discharge the frozen confection from the other end of the pod while continuing to rotate the mixing paddle inside the pod. A method comprising **Claim 34** The method according to claim 33, wherein the initial mixing speed is 50 RPM or more at the start of the refrigeration cycle, and the higher mixing speed is 300 RPM or more during the refrigeration cycle. **Claim 35** The method according to claim 34, further comprising dispensing the frozen confection when the temperature of the frozen confection is between 17 degrees Fahrenheit and 26 degrees Fahrenheit and the rotational speed of the mixing paddle is 100 RPM or more. **Claim 36** The method according to claim 33, wherein increasing the rotational speed of the mixing paddle comprises changing the rotational speed from 100 RPM to 1200 RPM while freezing the frozen confection. **Claim 37** The method according to claim 33, wherein the higher mixing speed is 800 RPM. **Claim 38** The method according to claim 37, further comprising continuously rotating the mixing paddle at the higher mixing speed while dispensing the frozen confection. **Claim 39** The method according to claim 33, wherein increasing the rotational speed of the mixing paddle from the initial mixing speed to the higher mixing speed comprises increasing the rotational speed of the mixing paddle at a rate between 40 RPM and 242 RPM per 15 seconds while freezing the frozen confection. **Claim 40** The method according to claim 33, wherein the higher mixing speed is 1000 RPM. **Claim 41** The method according to claim 33, wherein the initial mixing speed is 275 RPM. **Claim 42** The method according to claim 33, wherein the initial mixing speed is 50 RPM. **Claim 43** The method according to claim 33, further comprising warming the recess while dispensing the frozen confection. **Claim 44** Warming the recess is started after starting the dispensing of the frozen confectionery, the method according to claim 43.

45. Warming the recess is performed using a bypass valve of the refrigeration system, the method according to claim 43.

46. Dispensing the frozen confectionery occurs over 4 to 12 seconds, the method according to claim 33.

47. The method according to claim 33, further comprising increasing the rotational speed of the mixing paddle inside the pod while dispensing the single-serving frozen confectionery from the pod.

48. A method comprising: Inserting a pod into the recess to provide a single-serving of frozen confectionery while the recess of the machine is in the open position, the pod containing material for providing the single-serving of frozen confectionery; Moving the recess from the open position to the closed position to bring the side wall of the pod into contact with the side wall of the recess; While the side wall of the recess is in contact with the side wall of the pod and the recess is in the closed position, Using the refrigeration system of the machine to cool the side wall of the pod containing the material; Rotating the drive shaft of the machine at more than 50 RPM to mix the material to produce a frozen confectionery, the average diameter of ice crystals in the frozen confectionery being 50 μm or less, the drive shaft being rotationally coupled to a helical mixing paddle disposed inside the pod, rotating the drive shaft comprising increasing the rotational speed of the mixing drive shaft from an initial mixing speed to a higher mixing speed of more than 200 RPM while cooling the frozen confectionery; Drawing air into the pod by rotating the helical mixing paddle inside the pod while cooling the side wall of the pod without using a pump; producing the single-serving frozen confection from the materials within the pod; while continuously rotating the mixing paddle inside the pod, distributing the single-serving frozen confection from the pod by rotating the helical mixing paddle inside the pod so as to draw air into one end of the pod and discharge the frozen confection from the other end of the pod by the downward force generated by the rotation of the helical mixing paddle; A method comprising.

49. The method according to claim 48, further comprising increasing the rotational speed to 100 RPM during the production of the frozen confection.

50. The method according to claim 48, wherein the average diameter of the ice crystals in the frozen confection is less than 30 μm.

51. The method according to claim 48, wherein the rotational speed of the drive shaft is changed from 100 RPM to 1200 RPM while freezing the frozen confection.

52. The method according to claim 48, wherein the higher mixing speed is 800 RPM.

53. The method according to claim 52, further comprising continuously rotating the drive shaft at the higher mixing speed while distributing the frozen confection.

54. The method according to claim 52, wherein the higher mixing speed is 1000 RPM.

55. Increasing the rotational speed of the drive shaft from the initial mixing speed to the higher mixing speed comprises increasing the rotational speed of the drive shaft at a rate between 40 RPM and 242 RPM per 15 seconds while freezing the frozen confection, according to the method of claim 48.

56. The method according to claim 48, wherein the initial mixing speed is 275 RPM.

57. The method according to claim 48, wherein the initial mixing speed is 50 RPM.

58. The method according to claim 48, further comprising warming the side wall of the pod while dispensing the frozen confection.

59. The method according to claim 58, wherein warming the side wall of the pod is started after starting the dispensing of the frozen confection.

60. The method according to claim 58, wherein warming the side wall of the pod is performed using a bypass valve of the refrigeration system.

61. The method according to claim 48, wherein dispensing the frozen confection occurs over 4 to 12 seconds.

62. The method according to claim 48, further comprising increasing the rotational speed of the mixing paddle inside the pod while dispensing the single-serving frozen confection from the pod.

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