Production line for producing compostable pods for brewing products and system for measuring and adjusting the relative humidity of biodegradable paper-based materials

Abstract

The invention relates to a production line 1 for manufacturing compostable pods 5 for brewed products 5a, the pods being made from two complementary parts 4a, 4b, 6. The production line comprises a moulding line 2 for moulding the complementary parts, the moulding line comprising: The forming line comprises a handling unit for handling a sheet 3 of a biodegradable paper-based material with a gas-barrier biodegradable polymer, a moistening unit 8 for moistening at least one side of the sheet, a forming unit for forming the sheet into one of the complementary parts, and a drying unit 10 for drying at least one side of the sheet forming one of the complementary parts. According to the invention, the forming line comprises humidity sensors S1, S2, S3, S4 for detecting the level of relative humidity of the biodegradable paper-based material forming the pods, the humidity sensors being arranged before or after at least one of the handling unit, the moistening unit, the forming unit and the drying unit.

Description

[Technical Field]

[0001] The present invention relates to a device for manufacturing compostable pods for brewed products, comprising a humidity sensor, and to a humidity measurement and regulation system for such a device.

[0002] The invention further relates to a corresponding method for producing compostable pods for brewed products using the device, and to uses of the produced compostable pods.

[0003] The invention is particularly applicable in the food and beverage industry, and more particularly in the technical field of manufacturing pods for brewed products such as coffee and tea, adapted for the preparation of beverages in beverage preparation machines. [Background technology]

[0004] In recent years, packaging solutions such as capsules and pods have become increasingly popular in the field of brewed products, especially those adapted for brewing in beverage preparation devices such as home or commercial coffee machines. These capsules and pods store individual portions of the brewed product, protecting them from ambient air and mechanical or physical constraints. Thus, beverage preparation is easier and the time required to prepare the beverage is reduced. Furthermore, the proposed storage in capsules and pods makes it possible to obtain a high-quality beverage.

[0005] Coffee pods are known in the art and are currently widely used: WO 2006 / 057022 A1 and WO 2014 / 007639 A1 both describe coffee pods for use in coffee machines.

[0006] These pods are generally made of paper, as presented for example in WO 2005 / 092741 A1.

[0007] However, it is currently preferred to provide packaging that is at least biodegradable and / or possibly even compostable, with biodegradable paper or fiber-based materials being of particular interest.

[0008] In addition to the above requirements, the pod should also be airtight to protect the coffee from contact with air, which causes rapid oxidation and loss of aroma. To this end, the pod is made, for example, from a barrier paper-based material and is often laminated or coated to protect against moisture and / or oxidation.

[0009] Conventional manufacturing methods, which typically involve an embossing or thermoforming step of one of the sheets that form the pod, do not appear to be entirely satisfactory for producing such paper-based pods. For example, creases often appear around the stamped portion of the paper sheet.

[0010] A solution is presented in WO 202031096(A) which proposes moistening sheets of biodegradable material to improve pod formation.

[0011] However, the proposed manufacturing process does not appear to provide completely reproducible pod results, which is essential to ensure consistent pod quality and shelf life.

[0012] The present invention proposes to provide a solution to the above-mentioned problems by providing a suitable device and related manufacturing process. Summary of the Invention

[0013] In this respect, the present invention provides a manufacturing line for producing compostable pods for brewing products, the pods being made from two complementary parts, the manufacturing line comprising at least one moulding line for moulding the complementary parts, the moulding line comprising: a handling unit for handling sheets of biodegradable paper-based material having a gas-barrier biodegradable polymer; a moistening unit for moistening at least one side of the sheet of biodegradable paper-based material; an optional pre-drying unit for at least partially drying at least one side of the sheet of biodegradable paper-based material; a forming unit for forming a sheet of biodegradable paper-based material into one of the complementary parts; and a drying unit for drying at least one side of the sheet of biodegradable paper-based material forming one of the complementary portions.

[0014] According to the present invention, the forming line comprises at least one humidity sensor for detecting the relative humidity level of the biodegradable paper-based material forming the pods, the at least one humidity sensor being positioned before or after at least one of the handling unit, the humidifying unit, the optional pre-drying unit, the forming unit, and the drying unit.

[0015] In particular, it is an object of the present invention to provide a production line as claimed in claim 1 for producing compostable pods for brewing products, the pods being made of complementary first and second half shells made respectively from first and second sheets of biodegradable paper-based material. The claimed production line comprises a first moulding line for moulding the first half shells and a second moulding line for moulding the second half shells, each of the first moulding line and the second moulding line comprising: a handling unit for handling a sheet of biodegradable paper-based material, wherein one side of the sheet is defined as the inside and coated with a gas-barrier biodegradable polymer, and the other side of the sheet is defined as the outside; a moistening unit for moistening the exterior of the sheet of biodegradable paper-based material; an optional pre-drying unit for at least partially drying the exterior of the sheet of biodegradable paper-based material; a forming unit for forming the sheet of biodegradable paper-based material into half shells having an inner side corresponding to an inner side of the sheet of biodegradable paper-based material and an outer side corresponding to an outer side of the sheet of biodegradable paper-based material; and a drying unit for drying the outside and / or inside of the half shells.

[0016] According to the present invention, the forming line comprises at least one humidity sensor for detecting the relative humidity level of the biodegradable paper-based material forming the pod outside the pod, the at least one humidity sensor being positioned before or after at least one of the handling unit, the humidifying unit, the optional pre-drying unit, the forming unit, and the drying unit.

[0017] By sensing the relative humidity of the paper-based material from the pod at different locations and steps in the pod production, the humidity sensor allows for optimal control of this parameter along the production line, which is important as the level of humidity within the paper packaging can affect the shelf life of the final product, here the pod, and can affect the quality of the product contained by the paper packaging, here the brewed product.

[0018] The fact that the pod is made from two similar half shells results in duplication of the moulding lines.

[0019] The manufacturing line may also be designed to form pods comprising half shells and a cover membrane. In this case, the present invention provides a production line for producing compostable pods made from half shells and cover membranes that close the openings of the half shells, the half shells and the cover membranes being made from first and second sheets of biodegradable paper-based material, respectively, and the production line comprises a molding line for molding the half shells and a lid-forming line for forming the cover membranes. a handling unit for handling a sheet of biodegradable paper-based material, one side (B) of which is defined as the inside, coated with a gas-barrier biodegradable polymer, and the other side (A) of the sheet is defined as the outside; a moistening unit for moistening the outer side (A) of the sheet of biodegradable paper-based material, the moistening unit being optional for a lid-forming line; an optional pre-drying unit for at least partially drying at least the outer side (A) of the sheet of biodegradable paper-based material; a forming unit for forming the sheet of biodegradable paper-based material into a half shell or lid membrane having an inner side (B) corresponding to the inner side (B) of the sheet of biodegradable paper-based material and an outer side (A) corresponding to the outer side (A) of the sheet of biodegradable paper-based material, the forming unit being optional for a lid forming line; and a drying unit for drying the outside (A) and / or inside (B) of the half shells.

[0020] According to the present invention, the molding line and / or lid forming line comprises at least one humidity sensor for detecting the relative humidity level of the biodegradable paper-based material forming the pod outside the pod, the at least one humidity sensor being positioned before or after at least one of the handling unit, the humidifying unit, the optional pre-drying unit, the forming unit and the drying unit.

[0021] In particular, the at least one humidity sensor After the handling unit and before the humidification unit, and / or after the humidification unit and before the formation unit, and / or after the forming unit and before the drying unit, and / or It is located after the drying unit.

[0022] This allows the moisture content in the biodegradable paper-based material to be measured at different points in the production line to ensure control of the relative humidity of the paper-based material during the production process.

[0023] More particularly, the production line comprises a control unit that receives values ​​of relative humidity measured inline by at least one humidity sensor on the outside of the sheets and / or on the outside of the half shells of biodegradable paper-based material.

[0024] The advantage of the control unit is that it can regulate the humidity of the biodegradable material to a desired level, and furthermore it ensures that the level remains constant, thus ensuring a high process throughput.

[0025] According to a first possible feature of the production line, the control unit adjusts one or more parameters of the humidifying unit according to a value of relative humidity measured inline by a humidity sensor arranged after the handling unit and before the humidifying unit, and optionally further by a humidity sensor arranged after the humidifying unit and before the forming unit.

[0026] Using information about the relative humidity value, the moisturizing unit can adjust the moisture content in the biodegradable paper to an optimum level, which in turn allows the biodegradable paper to be formed under the best conditions.

[0027] In particular, one parameter of the humidification unit that is adjusted by the control unit is the amount of liquid used to humidify the outside of the sheet of biodegradable paper-based material, and the amount of liquid is adjusted by at least one or more of the liquid flow rate, liquid pressure, and humidification time.

[0028] Obviously, the amount of water applied to the biodegradable paper can be adjusted by various parameters, such as the water flow itself, water pressure, water temperature, nozzle spray time, number of nozzles, geometric configuration, etc. Having the right amount of water in the biodegradable paper allows the paper to deform under optimal conditions. Adjustments can be made based on one or more of these parameters as needed, which provides significant flexibility in the manufacturing process and adjustment system of the production line.

[0029] Indeed, applying the desired amount of liquid to the biodegradable paper ensures that the deformation takes place under optimal conditions, thus ensuring the paper pod formation without any damage such as cracks or wrinkles during production.

[0030] The additional parameters of the humidification unit adjusted by the control unit may be selected from a list of liquid type, liquid temperature, humidification unit settings, or a combination thereof, allowing optimal flexibility in adjustment.

[0031] For example, for optimal forming of the pod elements (half shells, lid membrane), the relative humidity measured on the outside of the sheet of biodegradable paper-based material by a humidity sensor placed after the humidifying unit and before the forming unit is between 15 and 30%.

[0032] The proposed installation makes it possible to have a wide range of humidity levels, thereby ensuring that the line can operate with different versions of biodegradable paper material, thereby guaranteeing the possibility of having paper pods with different properties.

[0033] According to a second possible feature of the production line, the control unit adjusts one or more parameters of the drying unit according to the value of the relative humidity measured in-line by a humidity sensor arranged after the forming unit and before the drying unit, and optionally also by a humidity sensor arranged after the drying unit. This feature ensures controlled and accurate drying of the paper material in the production line as required.

[0034] Specifically, one parameter of the drying unit adjusted by the control unit is selected from a list including the volume of the air flow, the temperature of the air flow, the dryness of the air, and the exposure time of the half shells to the air flow.

[0035] The ability to dry different levels of humidity results in an improved product by allowing the biodegradable paper to be humidified to an optimum humidity level for the transformation process.

[0036] Drying parameters are, for example, the volume of the air flow, the temperature of the air flow, the dryness of the air, the exposure time of the biodegradable paper to the air, and the geometrical settings.

[0037] Indeed, having different parameters for drying the biodegradable paper to the desired dryness level allows for operation with different humidity levels and different biodegradable paper types, minimizing energy consumption.

[0038] For example, for optimal formation of the pod elements (half shells, lid membrane), the relative humidity measured on the outside of the half shells of biodegradable paper-based material by a humidity sensor (S4) placed after the drying unit is less than 6%.

[0039] In fact, having a dry capsule is essential to meet food requirements, and in addition, consumers also expect a dry product. A wet capsule can stimulate microbial growth on the coffee pod and reduce the shelf life of the product.

[0040] According to a second possible feature of the production line, the control unit adjusts one or more parameters of the forming unit according to a value of relative humidity measured in-line by a humidity sensor arranged after the humidifying unit and before the forming unit.

[0041] Indeed, knowing the moisture level of the biodegradable paper allows optimal adjustment of the parameters of the forming tool in order to deform the paper under optimal conditions. Some of the parameters that can be adjusted in the forming tool are the temperature of the forming die and plunger, the speed of the plunger, the clamping force on the paper (the squeezing force of the upper and lower parts of the forming tool), and the cycle time of the forming process.

[0042] As mentioned above, the forming line of the production line may comprise a pre-drying unit, and optionally the control unit may adjust one or more parameters of the pre-drying unit according to the value of the relative humidity measured in-line by a humidity sensor (S1) arranged after the handling unit and before the pre-drying unit.

[0043] This is advantageous in that it allows the pre-drying unit to have much more flexibility in the forming process. For example, if the paper is too wet, it can be re-dried to ensure the required humidity level in the forming unit. This also helps to ensure that the biodegradable paper has the same humidity level across the area.

[0044] According to a further feature, the production line comprises: a filling unit for filling the half shells with a predetermined amount of brewed product; a press unit for compressing the brewed product in the half shells; a sealing unit for receiving a complementary half shell and sealing the two half shells together; and a cutting unit.

[0045] The invention further relates to a system for measuring and regulating the relative humidity of a biodegradable paper-based material forming a complementary part of a pod.

[0046] Therefore, according to another aspect of the present invention, a system for measuring and regulating the relative humidity of a sheet of biodegradable paper-based material is proposed, comprising: an in-line moistening unit for moistening the exterior of the sheet of biodegradable paper-based material that is formed into the half shells; an in-line drying unit for drying the exterior of the half shells made from the sheets of biodegradable paper-based material; an in-line humidity measurement system that measures the relative humidity on the outside of the sheet of biodegradable paper-based material and / or the outside of half shells made from the sheet of biodegradable paper-based material; An in-line humidity control system.

[0047] More specifically, the in-line humidity adjustment system adjusts the wetting of the exterior of the sheet of biodegradable paper-based material by adjusting the in-line moisturizing unit and / or adjusts the drying of the half shells made from the sheet of biodegradable paper-based material by adjusting the in-line drying unit based on the in-line humidity measurement system.

[0048] Advantageously, the various closed-loop control cycles allow the biodegradable paper to be transformed under optimal conditions. The closed-loop control cycles are applied continuously so that the production line and process can run continuously under optimal conditions.

[0049] As a further proposal, an in-line humidity control system controls the external wetness of the sheet of biodegradable paper-based material by adjusting the temperature of the forming unit.

[0050] Similarly, regulating the temperature of the forming unit has the advantage that the transformation of the biodegradable paper can take place under optimum conditions, ensuring that the paper pods comply with quality requirements.

[0051] Specifically, the in-line humidity measurement system comprises at least one humidity sensor for detecting the level of relative humidity on the outside of the sheet of biodegradable paper-based material and / or on the outside of a half shell made from the sheet of biodegradable paper-based material.

[0052] The benefit of measuring humidity levels at various stages of the process is to ensure that different units across the production line, humidification units and forming units, are operating at optimum conditions to ensure quality conforming paper pods.

[0053] According to a further aspect, the invention relates to a manufacturing process comprising measuring the relative humidity on at least one side of a sheet (3) of biodegradable paper-based material forming one of the complementary parts (4a, 4b, 6) of the pod (5) and adjusting the different steps of this process according to the relative humidity measured during one or more of the forming steps.

[0054] For this purpose, a method according to claim 18 is proposed for producing a compostable pod for brewing products made of a biodegradable paper-based material with gas barrier properties.

[0055] The manufacturing method is Providing a first sheet and a second sheet of a biodegradable paper-based material; forming the first sheet into at least a first half shell; forming the second sheet into a second half shell; placing a predetermined amount of brewed product into a first half shell; compressing a quantity of brewed product into a first half shell; and joining the first half shell to the second half shell to form a pod containing the brewed product. The step of forming the first and second sheets of paper-based biodegradable material into the first and second half shells of the claimed manufacturing method comprises: No. At least a first portion of the first sheet and a second portion of the second sheet at least wetting the second portion; measuring the relative humidity of a first portion of the first sheet and a second portion of the second sheet; forming the first and second portions to create the first and second half shells; drying the first half shell and the second half shell; measuring the relative humidity of the first half shell and the second half shell; and adjusting the wetting step and / or the shaping step and / or the drying step according to the relative humidity measured in one or more of the shaping steps.

[0056] The proposed manufacturing method allows to have a stable manufacturing process in which the pods produced have optimal quality.

[0057] According to a further aspect of the present invention, the proposed production line using a system for measuring and adjusting the relative humidity of the biodegradable paper-based material used to manufacture compostable pods using the proposed method for manufacturing compostable pods allows the use of compostable pods made from the biodegradable paper-based material according to claim 19. [Brief explanation of the drawings]

[0058] The present invention is further described with reference to the following examples, it being understood that the invention as claimed is in no way intended to be limited by these examples.

[0059] Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: [Figure 1a] 1 is a schematic cross-sectional view of a compostable pod according to the present invention. [Figure 1b] FIG. 2 is a schematic cross-sectional view of a compostable pod according to a second embodiment of the present invention. [Figure 2] 1 is a molding line of a packaging production line for compostable pods for brewing products according to the present invention. [Figure 3] 3 is a schematic diagram of a manufacturing line for packaging compostable pods for brewing products according to the present invention, incorporating the molding line of FIG. 2. [Figure 4] FIG. 10 is a schematic diagram of a molding line according to another embodiment of the present invention incorporating a pre-drying unit. DETAILED DESCRIPTION OF THE INVENTION

[0060] As used in this disclosure and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context dictates otherwise. Thus, for example, reference to "a fluid" or "the fluid" includes two or more fluids.

[0061] The terms "comprise," "comprises," and "comprising" should be interpreted as inclusive rather than exclusive. Similarly, the terms "include," "including," and "or" should all be interpreted as inclusive unless such a construction is clearly prevented from the context.

[0062] Notwithstanding this, devices and apparatuses disclosed herein may lack any element not specifically disclosed. Accordingly, disclosure of an embodiment using the term "comprising" includes disclosure of embodiments "consisting essentially of" the specified components, as well as embodiments "consisting of" the specified components. Similarly, methods disclosed herein may be absent from any step not specifically disclosed herein. Accordingly, disclosure of an embodiment using the term "comprising" includes disclosure of embodiments "consisting essentially of" the specified steps, as well as embodiments "consisting of" the specified steps.

[0063] The term "and / or" used in the context of "X and / or Y" is to be interpreted as "X" or "Y" or "X and Y". Similarly, "at least one of X or Y" is to be interpreted as "X" or "Y" or "X and Y". As used herein, the terms "example" and "for example", particularly when followed by a list of terms, are merely exemplary and illustrative and are not to be considered exclusive or inclusive. Unless otherwise stated, any embodiment disclosed herein can be combined with any other embodiment disclosed herein.

[0064] As used herein, "about" and "approximately" are understood to refer to numbers within a numerical range, e.g., within -10% to +10% of the referenced number, preferably within -5% to +5% of the referenced number, more preferably within -1% to +1% of the referenced number, and most preferably within -0.1% to +0.1% of the referenced number.

[0065] Quantifiers such as "first" and "second" are used merely to distinguish between components. These quantifiers do not imply the presence, relative placement, or any chronological order of other components. In this regard, the presence of a "second" construct does not necessarily imply the presence of a "first" construct. Furthermore, in this regard, a "second" element may be obtained and / or used before, after, or simultaneously with any "first" element.

[0066] Any reference herein to a prior art document should not be taken as an acknowledgement that such prior art is well known or forms part of the common general knowledge in the art.

[0067] FIG. 1a shows a schematic cross-sectional view of a compostable paper pod 5 made according to the present invention.

[0068] The pod 5 is made of two half shells 4a and 4b sealed together and encloses a predetermined amount of brewed product 5a. The brewed product may be, for example, coffee, tea, or another ingredient or mixture of ingredients used to prepare a beverage in a beverage preparation machine. Each half shell is provided with a rim 20, which allows for proper sealing and better handling of the pod by the consumer. The pod 5 is generally maintained in the beverage preparation machine using the rim 20.

[0069] Each half shell 4a and 4b is made from a sheet 3a, 3b of a biodegradable paper-based material having gas barrier properties.

[0070] Thus, the half shell 4 (either 4a or 4b) is made from a sheet 3 (either 3a or 3b) of biodegradable paper-based material having gas barrier properties by a specific forming process described later in this specification.

[0071] The gas barrier properties are provided by a coating applied to at least one side of the paper material.

[0072] The coating is essentially made of a biopolymer, such as PBAT, PBS, or PLA. By biopolymer is meant a biodegradable and / or compostable polymer. The biopolymer may be home- and / or industrially compostable in accordance with ongoing regulations.

[0073] More specifically, the term "compostable" means that the material will substantially decompose within a few months or weeks. It may be home compostable or industrially compostable. When industrially compostable, the material is at least about 90% composted under specified conditions within six months, as measured by the ISO 14855 or EN 13432 methods.

[0074] The polymer may be bio-based, i.e. made from non-petroleum based materials (monomers).

[0075] The paper material is parchment paper that has undergone a special treatment that allows it to be moldable.

[0076] In this case, the paper-based material is coated on one side with a biopolymer with gas barrier properties, such as those mentioned above as an example. The paper is initially in the form of a paper sheet with two sides: side A is defined as the outside and side B is defined as the inside.

[0077] The biopolymer is applied to the inside, side B, which at the end of the manufacturing process forms the internal housing of the pod 5. The biopolymer is therefore in contact with the brewed product.

[0078] These definitions of inside and outside A and B are also used for the half shells 4 and pod 5 according to the description. The inside B of the half shells 4a, 4b and pod 5 is the side that forms the housing for the brewed product. The outside A of the half shells 4 and pod 5 is the side that faces the outside of the pod.

[0079] In accordance with the present application, biodegradable paper-based materials are intended to include paper materials coated with biopolymers that have gas barrier properties. Currently used biodegradable paper-based materials are those from AHLSTROM MUNKJO.

[0080] The biodegradable paper-based material is provided as a sheet of biodegradable paper-based material on a roller.

[0081] For ease of understanding, the term paper is used herein to refer to biodegradable paper-based materials.

[0082] FIG. 1b shows a schematic diagram of a compostable paper pod 5 made according to another embodiment of the present invention. Here, the pod 5 comprises one half shell 4 and one flat membrane 6 sealed onto the half shell 4. As mentioned above, both parts of the pod 5 are made of a biodegradable paper-based material. One paper sheet 3a is shaped as the half shell 4, and the other paper sheet 3b forms a membrane covering the opening of the half shell 4. The membrane is generally flat or corrugated and may need to be shaped. In some cases, the membrane 6 may not be shaped, and the paper sheet is used directly (without pre-forming) after a preparation process, such as moistening and / or pre-cutting, as needed.

[0083] Figure 2 shows a moulding line 2 for half shells 4 (either 4a or 4b, the moulding lines of which are similar) made of biodegradable paper-based material, which is part of a production line 1 for compostable pods 5, which will be described in more detail. Both production line 1 and moulding line 2 are believed to be food compliant in production.

[0084] At its entrance, the forming line 2 is equipped with a handling unit 7 for storing and unrolling the paper. In the handling unit 7, the paper is unwound and presented for further processing along the line. The paper may remain part of the paper roll or may be cut into sections. In both cases, the term paper sheet is used.

[0085] Before being inserted into the handling unit 7, the paper rolls may be stored in a humidity controlled area.

[0086] Once unwound, the paper is inserted into the moisturizing unit 8 and advances.

[0087] The moistening unit 8 is intended to moisten at least one side of the sheet. In practice, the moistened side is the outer side A, the side that does not contain biopolymer.

[0088] The terms "moisten" and "humidify" are given the same meaning herein and are both used interchangeably.

[0089] The moisturizing unit 8 moistens the paper by spraying a liquid onto the paper. The moisturizing unit's spray configuration uses, for example, a spray nozzle.

[0090] Although the present embodiment proposes moistening the paper using spray elements in the moistening unit 8, other types of moistening devices may also be used, for example an applicator roller using a brush or a sponge.

[0091] The liquid is food-grade and completely safe for human consumption.

[0092] The liquid may be a water-based liquid (water with one or more additional elements that may improve formability) or water.

[0093] The water used can be from communes that have undergone a specific UV treatment, or it can be demineralized water resulting from a reverse osmosis process. The key is to have water that is perfectly compatible with food requirements.

[0094] The amount of water applied to the paper is adjusted in-line according to various parameters that affect the relative humidity level of the paper.

[0095] The amount of water can be adjusted by one or more of the following parameters: water flow, Water pressure, Water temperature can vary from 20 to 80°C. Nozzle spray time, Number of nozzles in use, Geometric settings of the nozzle.

[0096] As an example, the spray nozzle arrangement may include four nozzles for spraying water in an amount of 10 to 70 grams per square meter of paper.

[0097] The nozzle may be made of stainless steel and food grade sealing material (eg, food grade PTFE).

[0098] Upon leaving the moistening unit 8, the relative humidity of the paper should be between 15 and 30% in order to be properly shaped and to avoid cracks, wrinkles, or any other appearance defects on the formed half shells and their edges.

[0099] Once the paper sheet 3 has been moistened on its outside A, it enters a forming unit 9 for shaping the paper sheet into a desired shape, which in this case may be a half shell 4.

[0100] The forming unit 9 comprises a plunger and a cavity (not shown) between which the paper sheet 3 is placed.

[0101] The formation process can be divided into several steps.

[0102] The formation unit is cutting areas for cutting the paper sheet I at specific locations so as to release stresses on the paper sheet during and after the formation of the half shells; and a stamping area for forming (part of) the paper sheet into a half shell.

[0103] For example, before undergoing a particular shaping, the paper sheet 3 may be pre-cut at different locations (on the paper sheet) to reduce stresses that may be applied after the half shells 4 are formed. The paper pre-cuts may have different shapes and / or lengths according to the characteristics of the paper used. The pre-cutting unit is not shown.

[0104] In fact, the paper sheet 3 makes it possible to form a certain number of half shells 4, depending on its dimensions.

[0105] After optional pre-cutting of the paper sheet 3, the paper sheet 3 is placed between the subsequent plunger and the cavity.

[0106] The formation process is controlled by various parameters which can be combined where possible or necessary: The shape of the cavity and plunger; Cavity and plunger materials (surface roughness, material, friction, coating, etc. of the die and / or plunger); Speed ​​of movement, the clamping force applied to the paper, which makes it possible to crush wrinkles that appear during forming; the vacuum on the cavity side, the humidity level of the paper (relative humidity), Paper composition and properties, etc.

[0107] At the end of the forming unit 9 the paper sheet 3 is formed into a series of half shells 4 .

[0108] The half shells 4 are then dried to ensure a stable process and reproducible product delivery.

[0109] A drying unit 10 completes the forming line 2 .

[0110] The drying unit 10 dries the paper to a desired level, for example by blowing air onto the paper.

[0111] If the drying of the paper (in the form of half shells) is carried out by blowing air, the drying of the paper can be regulated by one or more of the following parameters: airflow volume, the temperature of the airflow, air dryness, The exposure time of the paper to air, geometric settings, etc.

[0112] When adjusting the drying of the paper based on the above parameters, the relative humidity of the air should be taken into account and the parameters should be adapted if the relative humidity of the air increases.

[0113] As an example, the proposed drying unit utilizes a total air flow rate of 2500-3000 cubic meters per hour, with the blown air having a temperature in the range of approximately 20°C to 40°C.

[0114] Alternative drying systems may be used without departing from the disclosed technical solution, for example a drying unit using heating means to dry the paper by sealed contact may be used.

[0115] At the end of the drying process, when the half shells leave the drying unit, the relative humidity of the paper forming the half shells must not be higher than 5%.

[0116] An adapted hygienic design ensures that food requirements are fully taken into account. For example, the air blown onto the formed paper (half shells) or membrane must be free of any contaminants. To reduce the risk of microbial development, the relative humidity of the air should be in the range of 30-70%.

[0117] The forming line 2 also comprises a series of sensors S1, S2, S3 and S4, which are humidity sensors that allow the detection of the relative humidity of the paper material when it is in the form of a sheet 3 or when it is formed as a half shell 4 or a film 6.

[0118] Sensors S1, S2, S3, and S4 measure the relative humidity on the outside (side A) of the paper in-line. The measurements help to control the entire process, and in particular to regulate the moisturizing unit 8, the forming unit 9, and the drying unit 10.

[0119] As can be seen in FIG. 2, sensor S1 is positioned after the handling unit and before the moisturizing unit, sensor S2 is positioned after the moisturizing unit and before the forming unit, sensor S3 is positioned after the forming unit and before the drying unit, and sensor S4 is positioned after the drying unit.

[0120] Thus, S1 records the relative humidity (RH) of the incoming paper after it has been handled by the handling unit 7.

[0121] S2 records the RH of the paper after the humidification unit, the RH at this stage of the process should be 15-30% to ensure good and accurate formation of the half shells.

[0122] S3 records the RH of the paper after the forming unit.

[0123] S4 records the RH of the paper after the drying unit; the RH at this stage of the process should be less than 6%, generally 2-6%, to ensure stable storage and an acceptable shelf life of the pods 5 (which, once formed, contain the brewed product).

[0124] One type of sensor that can be used is one that uses a microwave system.

[0125] The sensor measurement principle uses the microwave radiographic method: an electromagnetic field is applied that causes the water molecules to rotate (they are activated by microwaves). The dielectric loss is measured; the energy loss is an indicator of the water content in the paper.

[0126] Other types of sensors known to those skilled in the art may also be used.

[0127] In the proposed line, all sensors S1, S2, S3 and S4 are connected to a control unit 11 which analyses the relative humidity sensed at different unit locations of the forming unit and continuously adjusts different parameters of one or more of the humidifying unit, forming unit and drying unit. The adjustment can be performed using an adjustment module. Module R1 regulates the parameters of the humidification unit, the main parameters used for regulation being the amount of water applied, its temperature, time and water pressure. Module R2 adjusts the parameters of the forming unit, the main parameters being the temperature of one or more of the cavity and plunger, the speed of movement, and the clamping force. Module R3 regulates the parameters of the drying unit. The main parameters used for regulation are the amount of air blown, the temperature of the air, the dryness (relative humidity) of the incoming air, and the time the air is blown onto the paper.

[0128] This in-line humidity measurement and regulation of the relative humidity of the paper (in sheet form or molded as half shells or films) using a continuous closed-loop control system is particularly efficient in ensuring regular quality of the pods produced.

[0129] In one embodiment, the amount of water applied to the paper by the moisturizing unit is adjusted in-line according to the relative humidity values ​​measured by S1 and S2, and the amount of air blown onto the paper by the drying unit is adjusted in-line according to the relative humidity values ​​measured by S3 and S4.

[0130] The humidity regulation loop uses two basic regulation loops applied sequentially to the humidification unit (and related processes) and the drying unit (and related processes).

[0131] The humidification process can be adjusted as follows:

[0132] Sensors S1 and S2 are in-line and measure the moisture content of the paper before and after the moisturizing unit 8, respectively. If the value measured by S2 is lower than the set point (15-30% RH), a.Increase water flow, b. Increase the "nozzle open" time. If the value measured by S2 is higher than the set point (15-30% RH), a. Reduce water flow, b. Decrease the "nozzle open" time.

[0133] The values ​​of decrease or increase of the above parameters take into account the values ​​of RH measured by S1 and adapt them to a continuous regulation loop.

[0134] The drying process is adjusted as follows:

[0135] Sensors S3 and S4 are in-line and measure the relative humidity of the paper before and after the drying unit 10, respectively. If the value measured by S4 is lower than the set point (2~6%RH), a. Reduce airflow, b. Decrease the air temperature If the value measured by S4 is higher than the set point (2~6%RH), a.Increases airflow, b.Increase the air temperature.

[0136] The values ​​of decrease or increase of the above parameters take into account the values ​​of RH measured by S3 and adapt them to a continuous regulation loop.

[0137] In addition to the parameters mentioned above, additional parameters may also be adjusted to accelerate reaching the RH setpoint before the forming unit 9 and after the drying unit 10 .

[0138] For example, the temperature of the water used to moisten the paper and the temperature of the forming tools (cavities and plungers) in the forming unit can be adjusted. Forming tool: The temperature of the forming tool can be adjusted from 20°C to 120°C. Water sprayed onto the paper in the humidification unit: the temperature can be adjusted between 20 and 80°C.

[0139] The difference between the temperature of the water in the moistening unit and the temperature of the forming tool should be controlled to avoid thermal reactions on the paper. The maximum difference should be approximately 40°C, for example, the forming tool at 100°C and the water (moistening unit) at 60°C.

[0140] FIG. 3 shows a schematic diagram of a packaging production line 1 for the proposed compostable pods 5 according to the invention, incorporating the moulding line of FIG.

[0141] The packaging production line 1 includes a forming line 2a similar to the forming line described in Figure 2, which forms a lower half shell of biodegradable paper-based material as shown, and a second forming line 2b similar to the forming line described in Figure 2, which forms an upper half shell of biodegradable paper-based material as shown.

[0142] The forming line 2a thus forms half shells 4a arranged as pod lower parts from paper sheets 3a. In addition to the handling unit 7, the moistening unit 8, the drying unit 9 and the control unit 11 described in connection with Figure 2, the forming line also comprises a filling unit 12, a pressing unit 13, together with a measuring and regulating system.

[0143] The filling unit 12 places the brewed product 5a into the lower half shell 4a once the half shells are in the correct position within the filling unit. The filling unit may use an endless screw to deliver a predetermined amount of brewed product. The filling unit 12 should deliver the brewed product precisely so that it does not spread over the edges 20 of the half shells 4. Those skilled in the art may use other types of known filling means to achieve the same result.

[0144] The pressing station 13 is for compressing the brewed product 5a in the lower half shell 4a. The compression force and duration are adapted to the desired result of the compression. Ideally, the brewed product should be compressed in such a way as to avoid particles of the brewed product being dispersed in the lower half shell 4a or on the edge 20. The compressed brewed product is fully involved in the integrity of the pod 5. By way of example, the brewed product should be compressed sufficiently so that the pod 5 cannot be folded. Suitable designs of the pressing station 13 are known to those skilled in the art.

[0145] 2, forming line 2b forms half shells 4b arranged as pod tops from paper sheets 3b. In addition to handling unit 7, humidifying unit 8, drying unit 10, and control unit 11b, forming line 2b also includes a conveying line 16 for conveying half shells 4b forming the pod tops to forming line 2a at a location located after press station 13.

[0146] After both molding lines 2a and 2b meet at a common point where half shell 4b (forming the top of the pod) is placed on half shell 4a (forming the bottom of the pod), the production line 1 comprises a sealing station 14.

[0147] The sealing unit 14 seals the two half shells 4a and 4b together, thereby forming a closed cavity for the brewed product.

[0148] Using heat or ultrasonic sealing techniques, the biopolymer seals both half shells at their edges.

[0149] In front of the sealing unit there is provided a sensor S5 for measuring the relative humidity of the half shell 4a forming the bottom of the pod. The sensor S5 is connected to the control unit 11 and allows further adjustment of the relative humidity of the paper via the adjustment modules R1, R2 or R3 depending on the RH measurement.

[0150] A final cutting unit 15 is at the end of the production line and singulates the pods 5 by cutting the pods concentrically around the edges 20 .

[0151] The production line 1 may further comprise an end of line unit (not shown) for collecting and packaging the pods 5 .

[0152] In the proposed production line, sensors S1, S2, S3, S4 and S5 measure the relative humidity of the paper (defined outside) inline. These values ​​serve to control the entire process and regulate the moistening unit 8, the forming unit 9 and the drying unit 10.

[0153] In all units of production line 1, proper hygienic design is applied, which helps to meet any food requirements (food safety).

[0154] In another embodiment of the production line 1, the production line comprises a forming line 2 for forming half shells that form the lower part of the pods and into which the brewed product is placed, and a lid forming line for forming lid membranes for the half shells. The lid forming line comprises the same handling and drying units as the forming line 2. The lid forming line may further comprise a moistening line if stretching of the paper material is required to form the membrane. The forming unit is optional, as the lid membrane is a flat piece of biodegradable paper-based material as described above in connection with Figures 1a and 1b.

[0155] The same is true for the other units in the production line. The pod 5 thus formed is the pod shown in Figure 1b.

[0156] Figure 4 shows a schematic diagram of the forming line 2 described in relation to Figure 2, incorporating a pre-drying unit 17 positioned after the moistening unit 8. The pre-drying unit 17 has the same function as the drying unit 10 described above. In some specific cases, the pre-drying unit 17 may be required to better control the relative humidity of the paper prior to its formation in the forming unit 9. Pre-drying may be performed on both sides of the paper, if desired.

[0157] As an option not shown, the drying unit 10 may be combined in the forming unit 8, in which case they form a single entity. The humidity sensors may be rearranged as required.

[0158] Although the present invention has been described by example, it should be understood that variations and modifications can be made without departing from the scope of the invention as defined in the claims. Furthermore, where known equivalents exist for specific features, such equivalents are incorporated as if specifically referred to herein.

Claims

1. A manufacturing line (1) for producing compostable pods (5) for a brewed product (5a), said pods (5) being made from complementary first and second half shells (4a, 4b) made respectively from first and second sheets (3a, 3b) of a biodegradable paper-based material, said manufacturing line comprising a first moulding line (2, 2a) for moulding said first half shells (4a) and a second moulding line (2b) for moulding said second half shells (4b), each of said first and second moulding lines (2, 2a, 2b) comprising: a handling unit (7) for handling the sheet (3) of biodegradable paper-based material, one side (B) of which is defined as the inside and is coated with a gas-barrier biodegradable polymer, and the other side (A) of the sheet is defined as the outside; a moistening unit (8) for moistening the outer side (A) of the sheet (3) of biodegradable paper-based material; an optional pre-drying unit (17) for at least partially drying at least said outer side (A) of said sheet (3) of biodegradable paper-based material; a forming unit (9) for forming the sheet (3) of biodegradable paper-based material into a half shell (4) having an inner side (B) corresponding to the inner side (B) of the sheet (3) of biodegradable paper-based material and an outer side (A) corresponding to the outer side (A) of the sheet (3) of biodegradable paper-based material; a drying unit (10) for drying the outside (A) and / or the inside (B) of the half shells (4), the first and / or second forming line (2a, 2b) comprises at least one humidity sensor (S1, S2, S3, S4) for detecting the relative humidity level of the biodegradable paper-based material forming the pod (5) on the outside (A) of the pod, the at least one humidity sensor (S1, S2, S3, S4) being arranged before or after at least one of the handling unit (7), the humidifying unit (8), the optional pre-drying unit (17), the forming unit (9), and the drying unit (10); 1. A production line comprising: a control unit (11) receiving values ​​of relative humidity measured inline by the at least one humidity sensor (S1, S2, S3, S4) on the outside (A) of the sheet (3) of biodegradable paper-based material and / or on the outside (A) of the half shells, wherein the control unit is further characterized in that it adjusts one or more parameters of the moisturizing unit (8) according to the values ​​of relative humidity measured inline by the humidity sensor (S1) arranged after the handling unit (7) and before the moisturizing unit (8), and optionally also by the humidity sensor (S2) arranged after the moisturizing unit (8) and before the forming unit (9).

2. A manufacturing line (1) for producing compostable pods (5) for brewed products (5a), the pods (5) being made from half shells (4) and a cover membrane (6) closing the openings of the half shells (4), the half shells (4) and the cover membrane (6) being made from a first sheet and a second sheet (3a, 3b) of a biodegradable paper-based material, the manufacturing line comprising: a molding line (2) for molding the half shells (4) and a lid-forming line for forming the cover membrane (6), the molding line (2) and the lid-forming line comprising: a handling unit (7) for handling the sheet (3) of biodegradable paper-based material, one side (B) of which is defined as the inside and is coated with a gas-barrier biodegradable polymer, and the other side (A) of the sheet is defined as the outside; a moistening unit (8) for moistening the outer side (A) of the sheet (3) of biodegradable paper-based material, the moistening unit (8) being optional for the lid-forming line; an optional pre-drying unit (17) for at least partially drying at least said outer side (A) of said sheet (3) of biodegradable paper-based material; a forming unit (9) for forming the sheet (3) of biodegradable paper-based material into a half shell (4) or lid membrane (6) having an inner side (B) corresponding to the inner side (B) of the sheet (3) of biodegradable paper-based material and an outer side (A) corresponding to the outer side (A) of the sheet (3) of biodegradable paper-based material, the forming unit (9) being optional for the lid forming line; a drying unit (10) for drying the outside (A) and / or the inside (B) of the half shells (4), the forming line (2) and / or the lid forming line comprises at least one humidity sensor (S1, S2, S3, S4) for detecting the relative humidity level of the biodegradable paper-based material forming the pod (5) on the outside (A) of the pod, the at least one humidity sensor (S1, S2, S3, S4) being arranged before or after at least one of the handling unit (7), the humidifying unit (8), the optional pre-drying unit (17), the forming unit (9), and the drying unit (10); 1. A production line comprising: a control unit (11) receiving values ​​of relative humidity measured inline by the at least one humidity sensor (S1, S2, S3, S4) on the outer side (A) of the sheet (3) of biodegradable paper-based material and / or on the outer side (A) of the half shell or the overmembrane (6), wherein the control unit is further characterized in that it adjusts one or more parameters of the humidifying unit (8) according to the values ​​of relative humidity measured inline by the humidity sensor (S1) arranged after the handling unit (7) and before the humidifying unit (8) and optionally also by the humidity sensor (S2) arranged after the humidifying unit (8) and before the forming unit (9).

3. At least one humidity sensor (S1, S2, S3, S4) after the handling unit (7) and before the humidification unit (8) (S1), and / or after the humidifying unit (8) and before the forming unit (9) (S2), and / or after the forming unit (9) and before the drying unit (10) (S3), and / or 3. A production line according to claim 1 or 2, characterized in that it is arranged after the drying unit (10) (S4).

4. 3. The production line according to claim 1 or 2, characterized in that one parameter of the moisturizing unit (8) adjusted by the control unit (11) is the amount of liquid used to moisten the outer side (A) of the sheet of biodegradable paper-based material, the amount of liquid being adjusted by at least one or more of the liquid flow rate, liquid pressure and moistening time.

5. 3. The production line according to claim 1 or 2, characterized in that one parameter of the humidification unit (8) adjusted by the control unit (11) is selected from the list of liquid type, liquid temperature, settings of the humidification unit, or a combination thereof.

6. 3. The production line according to claim 1 or 2, characterized in that the value of the relative humidity measured on the outside (A) of the sheet of biodegradable paper-based material by the humidity sensor (S2) arranged after the humidifying unit (8) and before the forming unit (9) is between 15% and 30%.

7. 3. The production line according to claim 1 or 2, characterized in that the control unit (11) adjusts one or more parameters of the drying unit (10) according to a value of relative humidity measured in-line by a humidity sensor (S3) arranged after the forming unit (9) and before the drying unit (10), and optionally further by a humidity sensor (S4) arranged after the drying unit (10).

8. 8. The production line according to claim 7, characterized in that one parameter of the drying unit (10) adjusted by the control unit (11) is selected from the list comprising the volume of the air flow, the temperature of the air flow, the dryness of the air, and the exposure time of the half shells to the air flow.

9. 7. The production line according to claim 6 when dependent on claim 1, characterized in that the relative humidity measured on the outside (A) of the half shells (4) of biodegradable paper-based material by a humidity sensor (S4) arranged after the drying unit is less than 6%.

10. A manufacturing line as described in claim 6 when dependent on claim 2, characterized in that the value of relative humidity measured on the outside (A) of the half shell (4) or the cover membrane (6) of biodegradable paper-based material by a humidity sensor (S4) arranged after the drying unit is less than 6%.

11. 3. The production line according to claim 1 or 2, characterized in that the control unit (11) adjusts one or more parameters of the forming unit (9) according to the value of relative humidity measured inline by the humidity sensor (S2) arranged after the humidifying unit (8) and before the forming unit (9).

12. 3. The production line according to claim 1 or 2, characterized in that the control unit (11) adjusts one or more parameters of the pre-drying unit (17) according to the value of the relative humidity measured in-line by a humidity sensor (S1) arranged after the handling unit and before the pre-drying unit.

13. The production line (1) a filling unit (12) for filling said half shells (4a) with a predetermined amount of brewed product (5a); a press unit (13) for compressing said brewed product (5a) in said half shells (4a); a sealing unit (14) for receiving the complementary half-shell (4b) and sealing the first half-shell (4a) to the second half-shell (4b) together; 2. The production line according to claim 1, further comprising a cutting unit (15).

14. The production line (1) a filling unit (12) for filling said half shells (4) with a predetermined amount of brewed product (5a); a press unit (13) for compressing said brewed product (5a) in said half shells (4); a sealing unit (14) for receiving the overlying membrane (6) and sealing the half shells (4) together to the overlying membrane (6); 3. A manufacturing line according to claim 2, further comprising a cutting unit (15).

15. A system for measuring and adjusting the relative humidity of biodegradable paper-based materials used to manufacture compostable pods (5), comprising: an in-line moistening unit (8) for moistening the outer side (A) of the sheet (3) of biodegradable paper-based material to be formed into the half shells (4); an in-line drying unit (10) for drying the outside (A) of the half shells (4) made from the sheet (3) of biodegradable paper-based material; an in-line humidity measuring system for measuring the relative humidity of the outer side (A) of the sheet (3) of biodegradable paper-based material and / or the outer side (A) of the half shells (4) made from the sheet (3) of biodegradable paper-based material; an in-line humidity control system, The in-line humidity adjustment system adjusts the wetting of the outer side (A) of the sheet (3) of biodegradable paper-based material by adjusting the in-line humidifying unit (8) and / or the drying of the half shells (4) made from the sheet (3) of biodegradable paper-based material by adjusting the in-line drying unit (10) based on the in-line humidity measurement system.

16. 16. The system according to claim 15, characterized in that the in-line humidity adjustment system adjusts the wetting of the outer side (A) of the sheet (3) of biodegradable paper-based material by adjusting the temperature of a forming unit (9) for shaping the sheet (3) into the half shells (4).

17. 17. The system according to claim 15 or 16, characterized in that the in-line humidity measurement system comprises at least one humidity sensor (S1, S2, S3, S4) for detecting the level of relative humidity on the outside (A) of the sheet (3) of biodegradable paper-based material and / or on the outside (A) of the half shells (4) made from the sheet (3) of biodegradable paper-based material.

18. A method for producing a compostable pod (5) for a brewing product (5a) made of a biodegradable paper-based material with gas barrier properties, comprising: Providing a first sheet (3a) and a second sheet (3b) of biodegradable paper-based material; forming said first sheet into at least a first half shell (4a); forming said second sheet into a second half shell (4b) or overcoat (6); placing a predetermined amount of brewed product (5a) in said first half shell (4a); compressing said quantity of brewed product (5a) in said first half shell (4a); and joining said first half shell (4a) to said second half shell (4b) or to said cover membrane (6) to form a pod (5) containing said brewed product (5a), The step of forming the first and second sheets of paper-based biodegradable material into the first half shell (4a) and the second half shell (4b) or the overcoat (6) comprises: wetting at least a first portion of said first sheet (3a) and at least a second portion of said second sheet (3b); measuring the relative humidity of the first portion of the first sheet (3a) and the second portion of the second sheet (3b); forming the first and second parts to create the first half shell (4a) and the second half shell (4b) or the overcoat membrane (6); drying the first half shell (4a) and the second half shell (4b) or the overcoat membrane (6); measuring the relative humidity of the first half shell (4a) and the second half shell (4b) or the overcoat membrane (6); and adjusting the wetting and / or forming and / or drying steps according to the relative humidity measured during one or more of the shaping steps.

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