Methods and systems for autonomous processing and formulating of plant material

Abstract

An automated pressing device configured to form a geometric shape from dried plant material comprises a base platform having a lower plate comprising at least one lower die, a top platform fixedly positioned above the base platform, at least one upper punch extending downward from the top platform, aligned with the at least one lower die, a feed shoe comprising an inner lumen, positioned above the base platform, configured to deposit a quantity of flowable plant material onto the lower plate, a cooling element configured to maintain the inner lumen of the feed shoe at a temperature below a dew point, and a linear actuator configured to move the upper punch downward toward the lower plate and compress the quantity of flowable plant material into a geometric shape. A method of producing a puck from plant material is also disclosed.

Description

METHODS AND SYSTEMS FOR AUTONOMOUS PROCESSING AND FORMULATING OFPLANT MATERIALCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US Provisional Patent Application No. 63 / 600,072, filed on November 17, 2023, incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION

[0002] In the cannabis recreational and medical use industry , there are various forms for cannabis for users to consume, including cured flower, concentrates, oils, and edibles among others. Vaporizing oil has become a popular standard as the doses of specific cannabinoids are measured and can easily be used on demand by the consumer. Consumers who want a convenient non-smoking experience frequently turn to oil vaping. Users who prefer flower vaporization are forced to give up the convenience offered by an oil vape. Oils are engineered products and often include synthetic and weakly tested chemicals. Further, the cannabis plant has hundreds of minor chemicals that are not fully understood but are believed to impact the entourage effect and cannot be effectively replicated in synthesized oils. As such, while many consumers prefer the direct smoking or vaporizing of cured cannabis plant materials, these cured plant materials can be inconsistent in the user experience because of the highly variable cannabinoids in the product due to the heterogeneity of the cannabis plant itself. Further, burning and smoking dried plant material produces a smell and smoke plume that can be offensive to nearby individuals, especially in enclosed spaces. Lastly, vaporizing cured plant materials requires an inconvenient preparation process which can be unnecessarily burdensome and cause frustration.

[0003] Individual milling of cannabis plant material is time consuming and messy, and thus pre-rolls (prepared cannabis cigarettes) have become popular for smoking. There is no convenience equivalent to pre-rolls for flower vaporization. Further, dosing can be a significant challenge as Delta-9- tetrahydrocannabinol (THC) is psychoactive, and the pre-rolls or other direct plant material-smoking is not precise in quantifying THC content. Consuming too much can lead to an inability to function; while consuming too little can mean the user feels little or no effect. Because the material is obtained from plants which can constantly change in the potency of the product, the only way to manage dosing is to homogenize and mix plant material collected from different plants together. However, flower processing itself has its challenges. Industrial milling and compression at scale can be difficult due to the viscous,sticky nature of oils and resins contained in the plant. These oils and resins make conventional methods for processing plant material, for example by milling, difficult, expensive, slow, or in some cases impossible.

[0004] Thus, there is a need in the art for a homogenous dried plant product that is in an easy-to-use and an on-demand product for flower vaporization. Further, there is a need for a scalable system and method for milling and compressing cannabis plants which allows for packaging the resulting material more efficiently. The present invention satisfies this unmet need.SUMMARY OF THE INVENTION

[0005] In one aspect, an automated pressing device configured to form a geometric shape from dried plant material comprises a base platform having a lower plate comprising at least one lower die, a top platform fixedly positioned above the base platform, at least one upper punch extending downward from the top platform, aligned with the at least one lower die, a feed shoe comprising an inner lumen, positioned above the base platform, configured to deposit a quantity of flowable plant material onto the lower plate, a cooling element configured to maintain the inner lumen of the feed shoe at a temperature below a dew point, and a linear actuator configured to move the upper punch downward toward the lower plate and compress the quantity of flowable plant material into a geometric shape.

[0006] In one embodiment, the at least one upper punch comprises two upper punches, and the at least one lower die comprises two lower dies. In one embodiment, the linear actuator comprises a servo motor in a rack and pinion configuration. In one embodiment, the feed shoe is movably mounted to the base platform via a linear actuator configured to move the feed shoe along a horizontal axis parallel to a top surface of the base platform. In one embodiment, the device is configured to move the feed shoe between an extended position, where an outlet of the feed shoe is directly over the at least one lower die, and a retracted position, where the outlet of the feed shoe is offset from the at least one lower die. In one embodiment, the cooling element comprises a pump configured to circulate a cooling fluid through at least a portion of the feed shoe.

[0007] In one embodiment, the device further comprises a discharge chute extending downward from the base platform. In one embodiment, the feed shoe further comprises a knock off bar mounted to a front of the feed shoe, configured to push the puck off of the at least one lower die and into the discharge chute. In one embodiment, the geometric shape formed is a puck, a tablet, a sphere, a cylinder, a pyramid, an ovoid, or any other 3 -dimensional shape. In one embodiment, the geometric shape formed is a puck with acentral hole. In one embodiment, the geometric shape formed is a puck without a central hole. In one embodiment, the device further comprises a milling machine configured to grind and chill the dried plant material into a flowable, dried plant material. In one embodiment, the milling machine comprises a grinding mesh. In one embodiment, the device further comprises a freeze drying device configured to remove excess moisture from the dried plant material.

[0008] In one aspect, a method of producing a puck from plant material comprises freeze drying the plant material to remove excess moisture, milling the freeze dried plant material into a flowable plant material, dispensing the flowable plant material onto a lower plate of a pressing device, and stamping the flowable plant material between an upper punch and the lower plate to form a puck. In one embodiment, the method further comprises the steps of moving a lower die to a distance below a top surface of the lower plate to form a cavity in the lower plate, and dispensing the flowable plant material into the cavity. In one embodiment, the method further comprises the step of moving the lower die to a position flush with a top surface of the lower plate to eject the formed puck from the cavity.

[0009] In one embodiment, the method further comprises the step of dispensing the flowable plant material onto the lower plate via a feed shoe comprising an inner lumen. In one embodiment, the method further comprises the step of moving the feed shoe from a retracted position, where the outlet of the feed shoe is offset from the lower plate, to an extended position, where the outlet of the feed shoe is positioned over the lower plate. In one embodiment, the method further comprises the step of actively cooling the feed shoe.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Fig. 1 is an isometric view of an exemplar}' double punch pressing device.

[0011] Fig. 2 is an isometric view of an exemplar}' double punch pressing device with the feed shoe removed.

[0012] Fig. 3 is an isometric view of an exemplar}' pressing device with axes for reference.

[0013] Fig. 4 is a lower isometric view of an exemplary pressing device.

[0014] Fig 5 shows an exemplary press, including a top view 501, a front view 502, and a side view 503 showing exemplary overall dimensions

[0015] Fig. 6 shows a cutout view of the assembly of a single upper punch and tips for an exemplary press, comprising of a single side of upper punch bushing, a die cooling block, socket flat-head screws, and lower punch bushing, among other parts.

[0016] Fig. 7A shows a lower tool assembly of an exemplary press including a total exploded view showing the core rod assembly.

[0017] Fig. 7B shows an exemplary puck formed by the systems and methods disclosed herein.

[0018] Fig. 8 shows the end of the feed shoe including the wear strip.

[0019] Fig. 9 is a process schematic for a method of producing a cannabis puck for vaporization.DETAILED DESCRIPTION

[0020] In one aspect, the present invention provides a system and an automated process using such system for producing a compacted geometric form of substantially homogenous dried cannabis plant material for purposes of vaporizing and inhaling by a user, which can also include additions or infusions of other non-cannabis plant or non-plant materials.

[0021] In another aspect, the present invention provides a sy stem and an automated process for inputting homogenous dried plant material as a flowable material and compressing such flowable material into a geometric form.

[0022] Plant material may comprise flower material, which flower material may be derived from a Cannabis or Hemp plant. In some aspects, the plant material is viscous and / or sticky at ambient conditions, or at Standard Temperature and Pressure (Imperial Units). In some aspects, plant material is chilled to a temperature suitable to facilitate shattering and / or grinding of the plant material. In some aspects, the chilling is achieved by addition of a chilling material, which may be a solid or a fluid. In some aspects, plant material is milled with a ball or masticating mill to a desired average particle size or size range. In some embodiments, the particle size range is between 500 and 1700 pm. In some aspects, the material produced by the milling is further dried by freeze-drying, for example to facilitate flow and minimize volatile compound losses. In some aspects, the processed material is a flowable material, whether powder or dry particulate. In some aspects, the flowable material is maintained at a desired temperature and / or humidity during the formulation process. In some aspects the produced, flowable material is formed into a puck or tablet, which may comprise an aperture therein and resemble a donut or bagel, by pressing. The material may be chilled and / or maintained at low humidity during pressing.Produced pucks or tablets may be suitable for vaping and / or smoking applications.

[0023] Another aspect of the invention includes system for earn ing out the methods described above, including one or more of: a ball or masticating mill or other suitable milling device; a chilling material for chilling the milling device and / or a pressing device: a freeze drying apparatus for freeze drying the milled material; and a pressing device for pressing the derived plant material into a tablet or puck.

[0024] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.Definitions

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present invention. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

[0026] The terms “comprise(s),” “include(s),” “having,’’ “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The singular forms “a,” “and” and “the” include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments “comprising,” “consisting of’ and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

[0027] “About” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass variations of ±20%, ±10%, ±5%, ±1%, and ±0.1% from the specified value, as such variations are appropriate.

[0028] Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges aswell as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6. from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.

[0029] The term “flowable material” is used herein to refer to dried plant powder or particulate that results from the milling processes disclosed herein. In some embodiments, flowable material includes plant-derived additives. In some methods disclosed herein, flowable material is provided as an input to an automated press in order to convert the flowable material into the desired packaged form of the flowable material, having in some embodiments a geometric form such as a puck or tablet. Flowable material as contemplated herein may have individual particles having a size in a range of between 1 pm and 1700 pm, or a size less than 1700 pm. In some embodiments, the flowable material as contemplated herein may have individual particles having a size in a range of between 1pm and about 1700 pm, or between 1 pm and 1600 pm, or between 1 pm and 1500 pm, or between 1 pm and 1400 pm, or between 1 pm and 1300 pm, or between 1 pm and 1200 pm, or between 1 pm and 1100 pm, or between 1pm and about 1000 pm, or between 1pm and about 900 pm, or between 1pm and about 800 pm, or between 1pm and about 700 pm, or between 1pm and about 600 pm, or between 1pm and about 500 pm, or any other suitable range. In various embodiments, the disclosed particle size ranges may describe 100% of the particles included in the flowable material, but in other embodiments, at least 99%, at least 98%, at least 97%, at least 96%, at least 95%, at least 94%, at least 93%, at least 92%, at least 91%, or at least 90% of the particles in a flowable material may fall within this size range. Flowable material may be dry such that the flowable material can traverse the surface of the automated press from an inlet through to a forming trough where the automated press produces the desired geometric form, such as a puck or tablet.

[0030] The term “automated” is used herein to refer to a machine process that, once set up, requires little or no human intervention to actuate or manipulate the flowable material. For the purposes of the term as used herein, routine quality control or intervention to correct issues is not considered human intervention. More specifically, the term “automated press” refers to an apparatus capable of receiving flowable material, and through automated processes take that flowable material and compress same into a geometric form for use, including as a puck or tablet.

[0031] The term “dry” as used herein refers to plant material or flowable material that has been freeze dried and undergoes the milling and the automated pressing steps in an environment that prevents condensation. A dry material may in some embodiments have a moisture content of less than 4% and insome embodiments the moisture content is less than 3%, or less than 2%, or in some instances less than 1%. The term “dry” used when referencing an environment refers to an environment having a temperature and humidity combination that prevents or significantly reduces condensation, e g., below the dew point.Description

[0032] The present disclosure relates to methods and systems for processing plant material for use in medicinal or recreational applications. “Plant Material” as referenced herein may refer in some exemplary embodiments to plant materials derived from or comprising cannabis or hemp, which can also include additions or infusions of other non-cannabis plant or non-plant materials. It is understood that the systems and methods disclosed herein are equally applicable to other organic or plant materials, including materials comprising or derived from tobacco, marshmallow, mint, sage, mullein, mugwort, skullcap, and coltsfoot, among other plants. In some embodiments, the plant or flower material is derived from a CBD dominant or a THC dominant cannabis plant, or from any other cannabis plant with or without full spectrum terpene profiles. Among the challenges associated with milling and / or processing certain plant materials, for example cannabis-derived flower material, by conventional means are issues associated with generating a flowable material having a sufficiently small average particle size to be suitable for pressing and producing a pressed formulation suitable for vaping applications. The present disclosure relates to surprising innovations that render plant material, including sticky and / or viscous plant material such as cannabis flower material, into a flowable material suitable for pressing, and having a sufficiently small particle size for use in vaping applications.

[0033] In some embodiments of the present disclosure, a plant and / or flower material is derived from a Cannabis plant. In some embodiments, a flower material is derived from one or more of cannabis sativa plants, hemp plants, cannabis indica plants, or cannabis ruderalis plants.

[0034] In some embodiments, the plant material is processed into a flowable material as disclosed herein. In further embodiments, the flowable material is then formed into a geometric shape, for example by flowing the flowable material into a forming trough or cavity and pressing the flowable material into the geometric shape. Suitable shapes include, but are not limited to, a puck, a tablet, a sphere, a cylinder, a pyramid, an ovoid, or any other shape. In some embodiments, the resulting geometric shape is suitable for smoking or vaping applications.

[0035] In some methods disclosed herein, the plant material and / or components of the systems or apparatus of the present disclosure are maintained in a dry or reduced- or controlled-humidityenvironment that prevents or severely limits condensation. Such environments may be held below the dew point during part or all of the milling and / or pressing process. Environments may be held in a dry state by a variety of climate control apparatus and design features, including but not limited to dehumidifiers, refrigeration apparatus, air- or water-tight seals, specialized ventilation systems, desiccant materials, or the like.Milling of Plant Material

[0036] In some embodiments, plant or flower material is ground to a particular size range, for use as a flowable material while minimizing volatile terpene and cannabinoid loss, by chilling the material before and during the grinding process disclosed herein. In some embodiments, an apparatus may comprise a milling apparatus such as a ball mill or tumbling machine or masticating grinder or cutting grinder configured to mill the plant or flower material into a flowable material. In preferred embodiments, a chilling material is added or injected into a tumbling area of the milling apparatus to cool a flower material therein. In some embodiments, the chilling material comprises a solid. In some embodiments, the chilling material comprises dry ice. In some embodiments, the chilling material comprises a chilling fluid. In some embodiments, the chilling fluid comprises a gas or liquid. In embodiments, a chilling material comprises a chilling gas, for example nitrogen or carbon dioxide. In some embodiments, the plant material can itself be chilled separately such that the plant or flower material will shatter when struck by ball or masticating mill. In some embodiments, once the plant or flower material is reduced to a desired size range, the resulting material is collected and transferred to the next step.

[0037] In some embodiments, the plant or flower material is milled with a ball or masticating or cutting mill. Milling machines as contemplated herein may be configured to spin or rotate either clockwise or counterclockwise. Depending on the type of milling system, with a static goal to reduce volatile compound losses from the grinding heat generation, milling machines may rotate at a speed up to a maximum of 500RPM.

[0038] During milling, the material may be maintained at cooled temperatures and / or reduced humidity, which may keep the material in a flowable state prior to subsequent steps. Some methods disclosed herein may include the step of freeze drying all or a subset of the material, before, during, or after the milling step.

[0039] In one embodiment, the frozen dried plant material is ground with a mesh having a size capable of creating a flowable material as disclosed herein, for example capable of traversing an automated press apparatus. Suitable mesh sizes include, but are not limited to, a 600-1500 micron mesh. In someembodiments the suitable mesh size is 620-1500 micron, or any other range of mesh size corresponding to a range of particle size disclosed here, for example resulting in material sizes from 1 to a maximum of 1500 microns. Once fully ground, the particulate material can be combined with a concentrate formula of any additive, including a specific cannabinoid or terpene or other functional additive, and then blended. The blending can be done by mixing the mixture in a bowl until fully blended, for example by mixing the mixture in the bowl at least 20 times, or alternatively in some embodiments at least 30 times, or at least 40 times, or at least 10 times. In some embodiments, a mixing step may comprise using a tumbler or other automated mixing apparatus to combine. An automated mixing apparatus as disclosed herein is any apparatus comprising a vessel into which the material(s) to be mixed are positioned and an agitating element configured to manipulate the materials, for example by rolling the vessel or by otherwise moving the material around within the vessel. Once mixed, a mesh wire strainer is used to strain the mixture and the desired strained material is collected a storage vessel, for example in a freeze dryer tray. In some embodiments a freeze dryer tray may comprise a metal, for example stainless steel. The strained material may then be placed in a freeze dryer or in an airtight container within a freezer, until it is ready to be fed into a forming apparatus.Freeze Drying

[0040] In some embodiments, excess humidity and moisture may be extracted from the plant or flower material by freeze-drying. The material may be cooled to a temperature below 10° F and then placed in an under 500 mTorr vacuum. The temperature may then be increased to about 70° F while still in the vacuum, using the well-understood sublimation process (frozen to vapor transition) to remove moisture. This freeze-dry process may have a duration between 3 hours to 16 hours. In some embodiments, a freeze-drying step may be applied to the plant or flower material prior to milling, after milling, and / or prior to formulation by pressing or compaction.

[0041] In some embodiments, the freeze drying step comprises the use of a freeze drying apparatus, for example a Harvest Right Freeze Dryer manufactured by Prep SOS, according to the recommended methods for use set out in the accompanying materials and / or manuals, the contents of which are incorporated by reference in their entirety.Non-condensation environment

[0042] In some embodiments, the automated pressing apparatus is used to form geometric shapes from the flowable material. In some embodiments, the automated pressing apparatus is positioned in an environment designed to reduce or prevent condensation, and preferably, this is an environment that isclose to or below the dew point. This enables the frozen and milled dried plant material, along with any additives as provided herein, to be homogenized and to travel through the automated pressing apparatus as flowable material in a flowable manner, i.e., without human direct actuation, to the final pressing stage and output of the desired formed geometric shaped plant mixture, such as a puck, a tablet, a sphere, a cylinder, a pyramid, an ovoid, or any other 3 -dimensional shaped tablet, in some embodiments a geometric shape with or without a central through hole, for example a puck shape with or without a through hole, or a donut.Regulation of Temperature and / or Relative Humidity

[0043] During the milling and / or pressing steps, depending on operating temperatures and ambient air conditions (namely, temperature and humidity and dew point), water vapor may condense onto the systems, including the systems of the present disclosure such as the automated pressing apparatus. Such condensation may foul the otherwise flowable material, reducing its free-flowing properties and preventing a uniform fill into a pressing die, or causing other problems such as damage to the system components via oxidation, or spoliation of plant material.

[0044] To mitigate this problem, temperature may be controlled based on the ambient relative humidity (RH). As anon-limiting example, to calculate this temperature, a dew point chart is shown in Fig. 10. Each line shows dew points at different relative humidity levels. If the feed shoe and die are maintained at a temperature below the line in the graph of Fig. 10 corresponding to the relative humidity, water will develop on feed shoe and die surfaces. To achieve proper operating conditions, the room temperature may be lowered or air dehumidified to achieve conditions conducive to dry operation.Formation of geometric shapes of compressed material, including puck-like form

[0045] With reference to Fig. 1, Fig. 2, Fig. 3, and Fig. 4, partial views of an exemplary pressing device according to the present disclosure are shown. The device is shown in a first view (Fig. 1) with the feed shoe 102 in the extended position, in a second view (Fig. 2) with the feed shoe 102 removed for clarity, and in a third view, (shown in top isometric and bottom isometric in Fig. 3 and Fig. 4, respectively) with the feed shoe 102 in the retracted position.

[0046] Mechanical drawings of an exemplary pressing device mounted on a cabinet are shown in Fig. 5. Note that the dimensions listed in Fig. 5 are in inches, and are for illustration purposes of one exemplary embodiment of the device only. The dimensions shown are not meant to limit the disclosed device in any way.

[0047] As shown in the figures, flowable material derived from the milling process described above may be stored for example in a reservoir 103, then may pass via feed shoe 102 (see Fig. 1) onto dies 604 (see Fig. 6) on plate 601 positioned on base platform 109. The feed shoe 102 may then be moved from the extended position to the retracted position (see Fig. 3) to expose dies 604, which are now filled with a quantity of flowable material. The feed shoe 102 may be moved between the extended and retracted positioned for example by linear actuator 105.

[0048] The flowable material may then be formed by pressing into a geometric shape, including a puck or tablet, which may be suitable for vaping or smoking applications. The pressing action may in some embodiments be performed by linearly actuating punches 602 having formed tips 603 downward along vertical axis 111 from top platform 108 downward toward dies 604 on plate 601, and compressing the flowable material between formed tips 603 and dies 604. In some embodiments, the flowable material is mixed into a homogenous mixture. In some embodiments, the reservoir 103 may comprise a vacuum insulated container, configured to be fed by gravity through a chilled feed shoe 102 to a die cavity 604. In some embodiments, the linear actuator 105 may comprise a rotary servo actuator and a linear gear in a rack and pinion arrangement, where the rack and pinion translates the rotational motion of the servo motor to linear motion of the feed shoe 102 along axis 112. The device may in some embodiments be configured to ‘shake’ the feed shoe 102, for example by moving the feed shoe 102 back and forth along axis 112 to facilitate movement of the flowable material down the feed shoe and fill the die cavity 604.

[0049] In some embodiments, after die-fill, the feed shoe 102 retracts out of the compression area along axis 112 and the upper tool tip 603 lowers into the die cavity 604. In embodiments, the upper tool 602 lowers and the lower tool raises plate 601 to compress the flowable material interposed between the punch tips 603 and 604. Movement of the upper and lower punches 602 and 106 may be controlled by servo-actuated motors (not shown) situated above and below the press frame. The compression profile may be controlled by software using ‘virtual cams’ to govern the motion and speed of the punches.

[0050] In some embodiments, after compression, the upper tool 602 retracts up and out of the die 604 and the lower tool 106 ejects the compressed tablet up and out of the die cavity 604. In some embodiments, the feed shoe 102 then moves to the extended configuration (see Fig. 1) and the knock off bar 107 mounted to the face of the feed shoe 102 separates the tablet from the lower punch face 601 and pushes it to the discharge chute 101. From this position, the lower tool 106 retracts to the die fill position, the die cavity 604 is filled with flowable material from feed shoe 102, and the process may repeat.

[0051] In some embodiments, an apparatus as disclosed herein can include a press, for example a 3- phase, 480V press; and a quantity of coolant, including but not limited to liquid nitrogen, water / anti-freeze mix, or a phase change material, for example freon. The depicted embodiment comprises two punch and core rods 602, but in other embodiments an apparatus may comprise 1, 3, 4, 5, 6, 7, 8, 9, 10 or more punches and core rods 602 in any arrangement. In some embodiments, some or all of the punches and core rods 602 may be arranged in a coplanar configuration. In some embodiments, an apparatus may comprise some punches and core rods 602 in active use and some kept as spares. In some embodiments, the punches and core rods 602 may be hot-swappable or easily replaced.

[0052] An exploded view of the upper punch is shown in Fig. 7A, comprising the punches 705, core rods 703, punch column 701, and set screws 704 and 706. The core rods 703 are stationary around the lower punch 705 and their purpose is to create a hole in the puck once it is formed. An exemplary puck 750 is shown in Fig. 7B. As shown in Fig. 7B, the exemplary finished puck has a shape of a cylinder having a diameter 751 and a height 752. The cylinder may further comprise a hole 754 having a diameter 753, positioned at the central axis of the cylinder, as shown. The diameter 751 of a puck produced by the systems and methods disclosed herein may be between 0.5 cm and 2 cm, or about 1.5 cm. The height 752 of the puck may be between 0.2 cm and 0.8 cm, or the diameter 753 of the hole 754 may be in a range of 10% to 90% of the diameter 751 of the cylinder.

[0053] Fig. 8 is a detail view of an outlet of an exemplary feed shoe 102, showing the inner shape 801 of the feed shoe 102. The depicted feed shoe further comprises a wear strip 802 configured to reduce wear on the outlet of the feed shoe from contact with the base platform.

[0054] An apparatus as disclosed herein may comprise a cleaning system kit and / or a dedicated tool box. In some embodiments, an apparatus may comprise an extra punch face metal scraping unit 107.

[0055] In one embodiment, a press as disclosed herein may have some or all of the following specifications shown below in Table 1. It is understood that the below specifications are provided as an example only, and are not by themselves meant to be limiting of the devices and methods disclosed herein.Table 1

[0056] In some embodiments, the plant material is maintained at a chilled temperature and / or low humidity during the pressing process in order to maintain a flowable state and avoid complications due to material becoming sticky and or viscous at ambient conditions. Specifications for an exemplary press used in formulating pucks or tablets of the present disclosure are set out in the following list of characteristics:

[0057] A system as disclosed herein may have a depth of fill (i.e., the depth of a cavity formed when upper punch die 604 is in a lowered position) of 5 mm to 20 mm below the plate, and a lower punch die of 15 mm to 38 mm below the plate, A system as disclosed herein may have a maximum pressing force of 1000 kg.

[0058] The upper punch stroke of a disclosed system, i.e. the distance between a lowered position and a retracted position of the upper punch tip 603, of between 50 mm and -20 mm.

[0059] The lower punch stroke of a disclosed system, i.e. the distance between a raised position and a retracted position of the lower punch die 604, may be between 0 mm and -40 mm. The lower punch stroke may be divided into a fill depth and an ejection depth, where in some embodiments the ejection depth is between 0.1 mm and 1 mm.

[0060] A puck or tablet produced by a system disclosed herein may have a maximum tablet diameter of between 5 mm and 25 mm. Systems disclosed herein may be capable of creating at least 30 tablets per minute (TPM) A press as disclosed herein may use a 2 phase or 3 phase power supply, for example a 3 phase power supply at 480 V alternating current (AC) at 30 A.

[0061] An example of a puck produced by systems and methods of the present disclosure is depicted in Fig. 7B.

[0062] Pucks or tablets produced by an apparatus disclosed herein may comprise one or more additives, including but not limited to vegetable glycerin, cannabis or non-cannabis-derived terpenes, and cannabinoid or non-cannabinoid isolates or concentrates, and non-cannabis additives. For the sake of convenience, embodiments are described with pucks as an example of the geometric shape produced by the automated pressing apparatus, however, the geometric shape is not limited to pucks, and could also be a tablet, a sphere, a cylinder, a pyramid, an ovoid, or any other shape. In some preferable embodiments, the geometric shape is a puck and the puck has a central hole to form a donut like shape. In some embodiments, additives may be sprayed on the pucks after production, for example to improve viscosity and vapor production of the pucks. In other embodiments, one or more additives may be added to the flowable material. The amount of additive may in some embodiments be up to 30% of the puck weight.

[0063] One aspect of the present disclosure relates to methods of producing pucks from an input material. One embodiment of this method is shown in Fig. 9. Although the method of Fig 9 comprises a certain number of steps arranged in a particular order, it is understood that different methods disclosed herein may comprise a subset of these steps, and / or may comprise some or all of the disclosed steps in a different order, and / or may comprise additional steps before, after, or between the steps in Fig. 9.

[0064] The method of producing pucks shown in Fig. 9 comprises the steps of obtaining a quantity of input material in step 901, freezing and grinding the input material in step 902, optionally blending the input material with an infusion material in step 903, freeze drying the frozen, ground, optionally blended input material in step 904, starting and preparing a puck press and preparing punches for the puck press in step 905, preparing the input material, loading a receptacle and feed shoe in step 906, optionally running a test puck run on the press to assess quality and weight in step 907, activating the puck press to run a production run of pucks at a speed of, for example, 1500 pucks per hour (pph) in step 908, periodically stopping the puck press for cleaning, for example once every 1000 pucks, in step 909, gathering the pucks in step 910, and packaging the pucks to make them ready for sale in step 911.EXPERIMENTAL EXAMPLES

[0065] A production run using the automated press disclosed herein was performed with the following input parameters on the apparatus (all in mm):

[0066] Upper punch entrance: 8.50; Tablet thickness: 4.5; Ejection: -0.05; Lower punch final: 13.00; Fill Position: 26.00; Under Fill Position: 26.00.

[0067] The room conditions where the automated press resides and the production run was performed were the following:60° F, 35% Humidity.

[0068] This production run produced 900 pucks per hour, (at a rate of about 15 pucks per minute). The pucks had a round donut shape, and the run was performed with 10% error rates. Imperfect pucks may be reground and repressed.

[0069] As pucks are consumed in a vaporizer, the puck’s vapor production, flavor and psychoactivity will decrease. This reduced production gives the user a good indication that the pucks are losing their effectiveness.

[0070] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is not intended that the invention be limited by the specific examples provided within the specification. While the invention has been described with reference to the aforementioned specification, the descriptions and illustrations of the embodiments herein are not meant to be construed in a limiting sense. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Furthermore, it shall be understood that all aspects of the invention are not limited to the specific depictions, configurations or relative proportions set forth herein which depend upon a variety of conditions and variables. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is therefore contemplated that the invention shall also cover any such alternatives, modifications, variations, or equivalents. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

[0071] It is understood that the foregoing detailed description and accompanying examples are merely illustrative and are not to be taken as limitations upon the scope of the invention, which is defined solely by the appended claims and their equivalents.

[0072] Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications, including without limitation those relating to the chemical structures, substituents, derivatives, intermediates, syntheses, compositions, formulations, or methods of use of the invention, may be made without departing from the spirit and scope thereof.

Claims

CLAIMSWhat is claimed is:

1. An automated pressing device configured to form a geometric shape from dried plant material, comprising: a base platform having a lower plate comprising at least one lower die; atop platform fixedly positioned above the base platform; at least one upper punch extending downward from the top platform, aligned with the at least one lower die; a feed shoe comprising an inner lumen, positioned above the base platform, configured to deposit a quantity of flowable plant material onto the lower plate; a cooling element configured to maintain the inner lumen of the feed shoe at a temperature below a dew point;. and a linear actuator configured to move the upper punch downward toward the lower plate and compress the quantity of flowable plant material into a geometric shape.

2. The device of claim 1, wherein the at least one upper punch comprises two upper punches, and the at least one lower die comprises two lower dies.

3. The device of claim 1, wherein the linear actuator comprises a servo motor in a rack and pinion configuration.

4. The device of claim 1, wherein the feed shoe is movably mounted to the base platform via a linear actuator configured to move the feed shoe along a horizontal axis parallel to a top surface of the base platform.

5. The device of claim 4, wherein the device is configured to move the feed shoe between an extended position, where an outlet of the feed shoe is directly over the at least one lower die, and a retracted position, where the outlet of the feed shoe is offset from the at least one lower die.

6. The device of claim 1, wherein the cooling element comprises a pump configured to circulate a cooling fluid through at least a portion of the feed shoe.

7. The device of claim 1, further comprising a discharge chute extending downward from the base platform.

8. The device of claim 7, wherein the feed shoe further comprises a knock off bar mounted to a front of the feed shoe, configured to push the puck off of the at least one lower die and into the discharge chute.

9. The device of claim 1, wherein the geometric shape formed is a puck, a tablet, a sphere, a cylinder, a pyramid, an ovoid, or any other 3 -dimensional shape.

10. The device of claim 1, wherein the geometric shape formed is a puck with a central hole.

11. The device of claim 1, wherein the geometric shape formed is a puck without a central hole.

12. An apparatus comprising the device of claim 1, further comprising a milling machine configured to grind and chill the dried plant material into a flowable, dried plant material.

13. The apparatus of claim 12, wherein the milling machine comprises a grinding mesh.

14. The apparatus of claim 12, further comprising a freeze drying device configured to remove excess moisture from the dried plant material.

15. A method of producing a puck from plant material, comprising : freeze drying the plant material to remove excess moisture; milling the freeze dried plant material into a flowable plant material; dispensing the flowable plant material onto a lower plate of a pressing device; and stamping the flowable plant material between an upper punch and the lower plate to form a puck.

16. The method of claim 15, further comprising the step of moving a lower die to a distance below a top surface of the lower plate to form a cavity in the lower plate; and dispensing the flowable plant material into the cavity.

17. The method of claim 16, further comprising the step of moving the lower die to a position flush with a top surface of the lower plate to eject the formed puck from the cavity.

18. The method of claim 15, further comprising the step of dispensing the flowable plant material onto the lower plate via a feed shoe comprising an inner lumen.

19. The method of claim 18, further comprising the step of moving the feed shoe from a retracted position, where the outlet of the feed shoe is offset from the lower plate, to an extended position, where the outlet of the feed shoe is positioned over the lower plate.

20. The method of claim 18, further comprising the step of actively cooling the feed shoe.

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