Method for preparing shaped powdered food or beverage products

Abstract

The present invention relates to a method of making a shaped powdered food or beverage product; the method comprising: (a) providing a powdered component; and (b) forming the powdered component into a desired shape to form a shaped powdered food or beverage product; wherein step (b) is performed by applying a compaction pressure of from 50 to 30,000 Pa while sintering the powdered component.

Description

[0001] METHOD FOR PREPARING SHAPED POWDERED FOOD OR BEVERAGE PRODUCTS FIELD OF THE INVENTION

[0002] The present invention relates to methods for preparing a shaped powdered food or beverage product, for example for reconstitution in a liquid to provide a food or beverage composition.

[0003] BACKGROUND TO THE INVENTION

[0004] Amorphous powders serve as raw and intermediate materials in different industries (e.g. pharmaceuticals, food, construction, and energy industries). In the food sector, for example, powders can facilitate transportation, mixing of ingredients as well as safe and efficient storage maintaining product quality. As a particular example, instant beverages are used to describe products such as milk, creamer, coffee, tea or the like which are sold in a form that can be reconstituted with water to form a drink. Such beverages are typically in solid, powdered form and are readily soluble in cold and / or hot water. Instant soluble coffee is a phrase used to describe coffee which has been prepared by extraction of roast and ground coffee to obtained a liquid extract followed typically by drying of the liquid extract into a powdered product by conventional means such as freeze-drying, spray-drying or the like. In order to prepare a beverage, cold or hot water is then simply added to the powder thus avoiding the complicated and time-consuming process which is involved when preparing a beverage, such as traditional roast and ground coffee.

[0005] Shaped powdered food or beverage products may be advantageous, for example, to provide specific dosage amounts and / or to reduce the packaging required in order to do so. Previous approaches for producing shaped powdered food or beverage products include compaction at very high pressures or freeze-drying. However, such approaches are associated with drawbacks including generation of products with poor reconstitution properties and high costs; respectively.

[0006] It is therefore desirable to provide shaped powdered food or beverage products which are suitably robust to withstand damage during - for example - processing and transportation. In addition, the shaped powdered food or beverage products should be capable of being dissolved / reconstituted in a liquid to provide a beverage within a convenient and acceptable time period for the consumer. Hence, it is desirable to provide shaped powdered food or beverage products which are suitably robust while providing good reconstitution properties.

[0007] SUMMARY OF THE INVENTION

[0008] The present inventors have determined that sintering of a powdered food or beverage component may be leveraged to generate a shaped powdered food or beverage product. In particular, it has been determined that combining the application of a low compaction pressure and sintering to a powdered food or beverage component allows a balance between surface tension and pressure effects to be achieved during the sintering. Without wishing to be bound by theory, this application of pressure-assisted sintering is considered to provide a powder processing step which facilitates the production of shaped powdered food or beverage products with favourable characteristics. For example, shaped powdered food or beverage products generated according to the present methods have been demonstrated to have advantageous mechanical resistance properties which may reduce damage during production, transport and / or storage. The present methods may be particularly advantageous for preparing a shaped powdered food or beverage product for reconstitution in a liquid to provide a food or beverage product, compared to a shaped powdered food or beverage product generated using high pressure compaction. For example, the present shaped powdered food or beverage products may provide beneficial reconstitution kinetics with faster reconstitution in a liquid, for example water, compared to shaped powdered food or beverage product generated using high pressure compaction. In particular, such good reconstitution kinetics may be achieved while maintaining a good mechanical resistance properties.

[0009] The methods of the present invention may therefore have particular utility in the production of a soluble shaped powdered creamer or coffee product, for example.

[0010] The present shaped powdered food or beverage products may also provide advantages of controllable dosage format compared to, for example, a traditional powder format. For example, the shaped powdered food or beverage products may be provided as multiple individual servings in a single packet. In contrast, it is more challenging to provide individual servings with a traditional powder format and, if multiple individual servings are provided in a single packet, additional packaging is required to separate the individual servings of a traditional powder. In a first aspect, the present invention provides a method of making a shaped powdered food or beverage product; the method comprising: (a) providing a powdered component; and (b) forming the powdered component into a desired shape to form a shaped powdered food or beverage product; wherein step (b) is performed by applying a compaction pressure of between 50 and 30,000 Pa while sintering the powdered component.

[0011] The present invention further provides a shaped powdered product obtainable by the method of the present invention.

[0012] The present invention further provides a shaped powdered food or beverage product comprising a sintered powdered component; wherein the shaped powdered food or beverage product has a porosity of 10% to 70% and maximum stress at rupture of 30 to 4000 N / cm2, preferably 100 to 2500 N / cm2.

[0013] DESCRIPTION OF DRAWINGS

[0014] Figure 1 - Deformation and breakage, a) Mould specifically designed to perform sintering under normal stress, creating cylindrical shapes, b) Three sintered samples prepared at 0.08,3.50 and 130kPa. c) Compaction Stress (σ) as a function of the longitudinal deformation (ε) during the compaction procedure for 10 samples of sintered powder at 3.5 kPa. d) Young’s modulus (E) as a function of the sintering pressure (P) and the Rumpf number (Ru). Error bars are given by the standard deviation over 10 different samples.

[0015] DETAILED DESCRIPTION

[0016] Various preferred features and embodiments of the present invention will now be described by way of non-limiting examples. This disclosure is not limited by the exemplary methods and materials disclosed herein, and any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of this disclosure. The skilled person will understand that they can combine all features of the invention disclosed herein without departing from the scope of the invention as disclosed. It must be noted that as used herein and in the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

[0017] The terms "comprising", "comprises" and "comprised of as used herein are synonymous with "including", "includes", "containing", or "contains", and are inclusive or open-ended and do not exclude additional, non-recited members, elements or steps. The terms "comprising", "comprises" and "comprised of also include the term "consisting of.

[0018] Numeric ranges are inclusive of the numbers defining the range.

[0019] The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that such publications constitute prior art to the claims appended hereto.

[0020] All publications mentioned in the specification are herein incorporated by reference.

[0021] Shaped powdered food or beverage product

[0022] The present invention provides a method of making a shaped powdered food or beverage product. In particular embodiments, the shaped powdered food or beverage product is suitable for reconstitution in a liquid to provide a food or beverage composition.

[0023] As used herein, a “shaped powdered food or beverage product” may refer to any three-dimensional shape. For example, the shaped powdered food or beverage product may be provided as any shape that can be produced using a production method that allows a compaction pressure of between 50 and 30,000 Pa to be applied to the product.

[0024] For example, the shaped powdered food or beverage product may be produced using a mould of the desired shape.

[0025] Suitably, the shaped powdered food or beverage product may be a cylinder, sphere, spheroid, cube, cuboid, cone, pyramid, lozenge, torus, heart, emoticon, shape of an animal, shape of a plant, shape of an object, shape of a symbol, shape of a letter, and other geometric, distinctive and / or organic shapes. Suitably, the shaped powdered food or beverage product may be a cylinder, sphere, spheroid, cube, cuboid, cone or pyramid.

[0026] Suitably, the shaped powdered food or beverage product may be a cylinder.

[0027] Suitably, the shaped powdered food or beverage product produced by the present method provides advantageous mechanical resistance properties - which may reduce damage during production, transport and / or storage. For example, the shaped food or beverage product may have beneficial ‘hardness’ properties which enable it resist mechanical damage.

[0028] Hardness or mechanical resistance properties may be determined by measuring the maximum stress at rupture of the shaped powdered food or beverage product. As used herein, ‘maximum stress at rupture’ may be defined as N / cm2. Suitably, maximum stress at rupture may be determined as shown in the present Examples. For example, maximum stress at rupture may be determined using a Texture Analyzer HDplusC (Stable Micro Systems) equipped with a load cell to crush the shaped food or beverage product, suitably at a constant speed. The maximum force can be extracted and divided by the shape cross-section surface to provide the maximum stress at rupture in N / cm2. By way of an illustrative example, a Texture Analyzer HDplusC may be equipped with a 500 kg load cell, to crush each shaped powdered food or beverage product vertically using a 3.5 cm-wide plate geometry at a constant speed of 0.5 mm / s.

[0029] Suitably, the shaped powdered food or beverage product may have a hardness (e.g. defined as maximum stress at rupture (N / cm2)) of 30 to 4000, 30 to 3000, 30 to 2500, 50 to 4000, 50 to 3000, 50 to 2500, 100 to 4000, 100 to 3000, 100 to 2500, 150 to 4000, 150 to 3000, or 150 to 2500 N / cm2.

[0030] Suitably, the shaped powdered food or beverage product may have a hardness (e.g. defined as maximum stress at rupture (N / cm2)) of 100 to 2500 N / cm2.

[0031] Suitably, the shaped powdered food or beverage product may have a hardness (e.g. defined as maximum stress at rupture (N / cm2)) of 150 to 2500 N / cm2.

[0032] Suitably, hardness may be determined by measuring the ability of the shaped powdered food or beverage product to withstand mechanical damage. For example, fragility of the shaped powdered food or beverage product may be assessed using a tumbler. Suitable tumblers are widely available, such as a Tumbler T-V-V-360 (Dumoulin). Fragility may be assessed by stirring the shaped powdered food or beverage product in the tumbler and visually evaluating the shapes and / or determining the weight of the shapes before and after tumbling. Illustrative parameters to assess fragility in a tumbler include using a Tumbler T-V-V-360 and stirring at a speed of 20% (30rpm) for 2 minutes. A shaped powdered food or beverage product may be determined to have suitable hardness if the weight of shaped powdered the food or beverage product decreases by less than 25%, less than 20%, less than 15% or less than 10% following a fragility test, such as described herein. This test is representative of mechanical damage that may be induced by friction, for example as during filling in pack processes.

[0033] Suitably, a shaped powdered food or beverage product may be determined to have suitable hardness if the weight of the shaped powdered food or beverage product decreases by less than 10% following a fragility test, such as described herein.

[0034] Powdered component

[0035] As will be apparent, a powdered component as described herein comprises particles.

[0036] In some embodiment, the powdered component may comprise an amorphous powder.

[0037] Suitably, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the powdered component may comprise an amorphous powder.

[0038] Suitably, at least 50%, at least 60%, at least 70%, at least 75%, at least 80%, and least 85%, at least 90%, at least 95%, or at least 99% of the powdered component may be amorphous.

[0039] Suitably, the powdered component is an amorphous powder.

[0040] Suitably, amorphous powder may be used herein to refer to a non-crystalline powder. An amorphous powder may possess a non-periodic array with highly-disordered atomic position. In other words, an amorphous powder may refer to a powder which is not a crystalline powder. The amorphous powder may be a glassy or rubbery solid. Suitably, the powdered component may be a powdered food or beverage component (i.e. a food grade powdered food or beverage component).

[0041] The powdered component may comprise soluble coffee - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, milk powder, powdered creamer, cocoa powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, malt powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, beverage powder, infant formula powder, fruit powder, powdered food for special medical purpose, soup powder, sauce powder, powdered bouillon, seasoning powder, vegetable powder, protein powder, nutritional powder, powdered food supplement, powdered flavours, powdered probiotic, vitamin and / or mineral powder, powdered prepared meal, carbohydrate powder, polysaccharide powder, a pharmaceutically active powdered ingredient and combination thereof.

[0042] The powdered component may comprise soluble coffee - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, milk powder, powdered creamer, or cocoa powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient.

[0043] The powdered component may comprise malt powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient.

[0044] Suitably, the powdered component comprises a soluble coffee powder; optionally further comprising sucrose and / or a foaming creamer.

[0045] As will be apparent the features described for the powdered component may also apply to the shaped powdered food or beverage product of the present invention.

[0046] In some embodiment, the powdered component is not milled or ground. In particular, the method of the invention does not comprise a step of milling or grinding before step (a), before step (b) and during step (b). In particular, the method of the invention does not comprise any step of milling or grinding. With the method of the invention, effective sintering is possible without requiring upstream milling or grinding. Milling or grinding generally disrupts the porous structure, in particular intervoid porosity of the powdered component which is key for providing good reconstitution properties. Hence, the absence of milling or grinding in the method of the invention will help to maintain the porous structure, in particular intervoid porosity of the powdered component. The maintenance of the porous structure, in particular intervoid porosity achieves good dissolution and reconstitution properties in the shaped powdered food or beverage product. As a consequence, the method of the invention is advantageous as it ultimately achieves effective sintering which provides good robustness to the shaped powdered food or beverage product while maintaining porous structure which retains good dissolution and reconstitution properties in the shaped powdered food or beverage product.

[0047] Compaction pressure

[0048] Suitably, the present invention provides a method of making a shaped powdered food or beverage product; the method comprising: (a) providing a powdered component; and (b) forming the powdered component into a desired shape to form a shaped powdered food or beverage product; wherein step (b) is performed by applying a compaction pressure and sintering the powdered component. Suitably, the compaction pressure is applied while sintering the powdered component.

[0049] The present methods generally comprise applying a compaction pressure of from 50 to 30,000 Pa.

[0050] As used herein, ‘applying a compaction pressure’ may refer to an active step of applying pressure to the powdered component in order to compress the particles of the powdered component. As such, the compaction pressure is applied in addition to the inherent powder weight of the powdered component. Suitably, a constant mass may be applied onto powdered component while sintering, to provide the compaction pressure.

[0051] Suitably, a compaction pressure from 50 to 30,000 Pa, 50 and 20,000 Pa, 50 and 10,000 Pa, 100 and 30,000 Pa, 100 and 20,000 Pa, 100 and 10,000 Pa, 50 and 5,000 Pa, 100 and 5,000 Pa, 50 and 3,000 Pa, or 100 and 3,000 Pa is applied.

[0052] Preferably, a compaction pressure from 100 to 3,000 Pa is applied. Suitably, the compaction pressure is applied as a uniaxial load. Accordingly, the compaction pressure is applied in a static manner. The compaction pressure is not applied in a dynamic manner. The compaction pressure is applied across the powdered component, i.e. across the whole volume or entirety of the powdered component.

[0053] Suitably, the uniaxial force is applied as a vertical force with lateral restriction. As will be apparent, ‘lateral restriction’ is used herein to refer to approaches which reduce or limit lateral strain during the compaction. Lateral restriction may be applied by use of a mould (e.g. as described herein).

[0054] By way of example, a compaction pressure may be applied by applying a constant mass to a shaped mould containing the powdered component.

[0055] Sintering

[0056] Sintering may refer to the formation of ‘bridges’ or ‘fusions’ between particles at temperatures below the melting point of a material. More particularly, when two particles (e.g. particles of a powdered component) are in contact at a temperature above the glass transition temperature (Tg), the contact is sintered through mass flow between particles, with an effective viscosity that depends on the distance to Tg. Sintering may therefore provide a process of forming a solid mass of powdered material, without melting the material to the point of liquefaction.

[0057] As such, sintering is initiated once the glass transition temperature is surpassed. Sintering may therefore be achieved by heating a base powder to a temperature above its glass transition temperature.

[0058] The glass transition temperature of a powder may be determined by Differential Scanning Calorimetry (DSC) or Thermal Mechanical Analysis (TMA) or Dynamic Mechanical Analysis (DMA) techniques by methods well known in the art. Models for determining the glass transition temperature (Tg) are also known in the art (Wong & Choi; Soft Matter; 45; 2019). Tgcan also be expressed vs. the water content of the product using the Gordon & Taylor equation (Gordon, M., & Taylor, J. S. (1952). Ideal copolymers and second-order transitions in synthetic rubbers. I. Non-crystalline polymers. Journal of Applied Chemistry, 2, 493-500). The glass transition temperature of powdered component can be higher or lower depending on the specific chemical composition and moisture level. The glass transition temperature can intentionally be raised or lowered by simply decreasing or increasing, respectively, the moisture content of the powdered component using any suitable method known to one skilled in the art, for example humidification or drying. Moisture content may also be measured using methods well-known in the art, for example thermogravimetric analysis (TGA). An example of TGA comprises measuring weight loss upon heating (2°C / min from 25°C to 180°C) until inflection point.

[0059] The powdered component may be heated to the sintering temperature by any suitable method known in the art, e.g. by convection, infra-red or microwave radiation, or heating elements in contact with the support.

[0060] Sintering may be performed using an oven to store the powder at a given temperature over its Tgfor a given amount of time.

[0061] Suitably, the sintering may be performed by heating the powdered component to a temperature 1°C to 70°C, 1°C to 60°C, 1°C to 50°C, 1°C to 40°C, 1°C to 30°C, 1°C to 20°C, 1°C to 10°C above its Tg. In particular, when the powdered component is made of plurality of components with the same Tgor made of the same component, the Tgof the powdered component is the Tgof the overall powdered component (which is the Tgof said component). When the powdered component is made of plurality of components with different Tg, the Tgof the powdered component is the Tgof the component with the lowest Tg.

[0062] Suitably, the sintering may be performed by heating the powdered component to a temperature at least 1°C, at least 5°C, at least 10°C, at least 20°C, at least 30°C, at least 40°C, at least 50°C, at least 60°C, or at least 70°C above its Tg. In particular, when the powdered component is made of plurality of components with the same Tgor made of the same component, the Tgof the powdered component is the Tgof the overall powdered component (which is the Tgof said component). When the powdered component is made of plurality of components with different Tg, the Tgof the powdered component is the Tgof the component with the lowest Tg. Suitably, the sintering may be performed by heating the powdered component to a temperature 30°C above its Tg. In particular, when the powdered component is made of plurality of components with the same Tgor made of the same component, the Tgof the powdered component is the Tgof the overall powdered component (which is the Tgof said component). When the powdered component is made of plurality of components with different Tg, the Tgof the powdered component is the Tgof the component with the lowest Tg.

[0063] The temperature at which sintering is carried out is may be from 30°C to 100°C, 30°C to 90°C, 30°C to 80°C, 40°C to 100°C, 40°Cto 90°C, 40°C to 80°C, 30°C to 70°C, or 30°C to 70°C.

[0064] Suitably, the sintering may be performed by heating the powdered component to a temperature from 40°C to 70°C.

[0065] As will be apparent, the sintering step should be carried out for a period of time which enables the necessary fusing of the particles without causing undesirable changes to the internal structure of the particles. The time period for which the sintering is performed may thus depend on the temperature.

[0066] The sintering may be performed for at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, at least 20, at least 21, at least 22, at least 23, at least 24, at least 25, at least 26, at least 27, at least 28, at least 29, at least 30, at least 31, at least 32, at least 33, at least 34, at least 35, at least 36, at least 37, at least 38, at least 39, at least 40, at least 41, at least 42, at least 43, at least 44, at least 45, at least 46, at least 47, at least 48, at least 49, at least 50, at least 51, at least 52, at least 53, at least 54, at least 55, at least 56, at least 57, at least 58, at least 59, or at least 60 minutes.

[0067] The sintering may be performed for at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, or at least 15 hours.

[0068] The sintering may be performed for less than 24 hours, preferably less than 15 hours, more preferably less than 10 hours, more preferably less than 6 hours, even more preferably less than 3 hours, even more preferably less than 2 hours, even more preferably less than 1 hour. The sintering may be performed for 1 to 24 hours, preferably 1 to 15 hours, more preferably 1 to 10 hours, more preferably 1 to 6 hours or even more preferably 1 to 3 hours.

[0069] Suitably, the sintering may be performed without forcing a gas through the powdered component. Suitably, the sintering may be performed without forcing a gas through the powder bed.

[0070] The total water content of the mixture is preferably kept constant during sintering so that no substantial amount of water is lost to the environment. If the heat treatment is performed in a closed environment, a minor amount of water may evaporate to the atmosphere within the closed environment.

[0071] The sintering is applied across the entirety or whole volume of the powdered component. In particular, the sintering is not applied only at the surface of the powdered component. The sintering and the compaction pressure are applied across the entirety or whole volume of the powdered component. The sintering and the compaction pressure are not applied only at the surface of the powdered component. As a consequence, the shaped powdered food or beverage product is sintered across its volume, i.e. across the entirety of the shaped powdered food or beverage product. In other words, the shaped powdered food or beverage product is not sintered only at its surface.

[0072] Contrarily to process involving sintering only of the surface of the powdered components, the process of the invention allows to create a homogeneously sintered shaped powdered food or beverage product across its whole volume. This provides mechanically more robust shaped powdered food or beverage products.

[0073] Average particle diameter

[0074] The powdered component may have an average particle diameter from 1 pm to 2500 pm.

[0075] The powdered component may have an average particle diameter from 1 pm to 2500 pm, 1 pm to 2000 pm, 1 pm to 1500 pm, 1 pm to 1250 pm, 1 pm to 1000 pm, 10 pm to 2500 pm, 10 pm to 2000 pm, 10 pm to 1500 pm, 10 pm to 1250 pm, 10 pm to 1000 pm, 20 pm to 2500 pm, 20 pm to 2000 pm, 20 pm to 1500 pm, 20 pm to 1250 pm, 20 pm to 1000 pm, 40 pm to 2500 pm, 40 pm to 2000 pm, 40 pm to 1500 pm, 40 pm to 1250 pm, 40 pm to 1000 pm, 60 pm to 2500 pm, 60 pm to 2000 pm, 60 pm to 1500 pm, 60 pm to 1250 pm, or 60 pm to 1000 pm.

[0076] The powdered component may have an average particle diameter from 20 pm to 1000 pm, more preferably from 60 pm to 1000 pm.

[0077] Methods for determining particle diameter are known in the art and include, for example, laser diffraction (e.g. Malvern Mastersizer) or imaging (e.g Camsizer X2), and powder dispersion under pressure (e.g. 1 or 2 bar). For example, particle size distribution may be measured using a laser granulometer such as a Mastersizer 2000 (Malvern Instruments, UK). For the measurements a sample may e.g. be dispersed in the Hydro SM measuring cell until an obscuration rate of 9-10% is obtained and then analysed in the Mastersizer.

[0078] Suitably, average particle diameter may be based on particle diameter distribution.

[0079] Average particle diameter may be determined as D10, D50 and / or D90, calculated from normalized curves, and corresponding to the particle diameter of 10 %, 50 % and 90 % of the particles; respectively.

[0080] Suitably, the average particle size may be the D50 average particle diameter size.

[0081] With wishing to be bound by theory, the present inventors have determined that the relationship between the compaction pressure and the average particle diameter of the powdered component particles may contribute to advantageous outcome of the present methods.

[0082] Accordingly, the product of the compaction pressure (P, pascal) and median volume particle diameter (D50) of the powdered component particles (d, pm) used in the present methods may be from 7,000 to 900,000.

[0083] As used herein, the “product” of the compaction pressure and average particle diameter of the powdered component particles refers to the mathematical expression of the value achieved by multiplication of the two values.

[0084] Suitably, the product of the compaction pressure (P, pascal) and average particle diameter of the powdered component particles (d, pm) used in the present methods may be from 7,000 to 900,000, from 7,000 to 800,000, from 7,000 to 700,000, from 7,000 to 600,000, from 7,000 to 500,000, from 7,000 to 400,000, from 7,000 to 300,000, from 10,000 to 900,000, from 10,000 to 800,000, from 10,000 to 700,000, from 10,000 to 600,000, from 10,000 to 500,000, from 10,000 to 400,000, from 10,000 to 300,000, from 15,000 to 900,000, from 15,000 to 800,000, from 15,000 to 700,000, from 15,000 to 600,000, from 15,000 to 500,000, from 15,000 to 400,000, from 15,000 to 300,000, from 20,000 to 900,000, from 20,000 to 800,000, from 20,000 to 700,000, from 20,000 to 600,000, from 20,000 to 500,000, from 20,000 to 400,000, from 20,000 to 300,000, from 30,000 to 900,000, 30,000 to 800,000, 30,000 to 700,000, from 30,000 to 600,000, from 30,000 to 500,000, from 30,000 to 400,000, or from 30,000 to 300,000.

[0085] Suitably, the product of the compaction pressure (P, pascal) and average particle diameter of the powdered component particles (d, pm) used in the present methods may be from 30,000 to 100,000.

[0086] Suitably, the product of the compaction pressure (P, pascal) and average particle diameter of the powdered component particles (d, pm) used in the present methods may be from 30,000 to 300,000.

[0087] Rumpf number (Ru)

[0088] It has also been determined that the relationship between the compaction pressure, the average particle diameter of the powdered component particles and the surface tension of the powdered component particles may contribute to advantageous outcome of the present methods.

[0089] For example, the combination of the compaction pressure (P, pascal), the average particle diameter of the powdered component particles (d, mm) and the surface tension of the powdered component particles (y, mN / m) may provide a Rumpf number (Ru) of 0.3 to 15, preferably 0.5 to 1.5; wherein Ru is calculated as: Ru=Pd / y.

[0090] Suitably, Ru may be 0.3 to 15, 0.3 to 10, 0.3 to 5, 0.3 to 2.5, 0.3 to 2, 0.3 to 1.5, 0.5 to 15, 0.5 to 10, 0.5 to 5, 0.5 to 2.5, 0.5 to 2, or 0.5 to 1.5.

[0091] Surface tension may be determined using methods known in the art. For example, using references of contact angle measurement with different liquids having known properties then fitting to extract surface tension (see, for example - Owens-Wendt-Rabel & Kaelble model: https: / / www.ossila.com / pages / a-guide-to-surface-energy).

[0092] Suitably, surface tension may be provided as y, expressed in mN / m.

[0093] Reconstitution

[0094] Suitably, the shaped powdered food or beverage product produced by the present method provides advantageous properties for reconstitution in a liquid.

[0095] For example, the present shaped powdered food or beverage products may provide beneficial properties which enable a short reconstitution time in a liquid (e.g. water) to provide a food or beverage product. In some embodiments, the shaped food or beverage product produced by the present method may provide an advantageous combination of resistance to mechanical damage and good reconstitution in liquid (e.g. water).

[0096] Suitably, the liquid may be water or milk. Preferably, the liquid may be water.

[0097] Reconstitution in water may be determined by measuring the time for a given amount of the shaped food or beverage product to dissolve in the liquid. Suitably, dissolution of the shaped food or beverage product may be determined in water. Suitably, the dissolution may be determined at a temperature between 20°C and 90°C, 30°C and 90°C, 40°C and 90°C, 50°C and 90°C, 60°C and 90°C, 70°C and 90°C. Suitably, the dissolution may be determined at a temperature between 20°C and 80°C, 80°C and 80°C, 40°C and 80°C, 50°C and 80°C, 60°C and 80°C, 70°C and 80°C. Suitably, the dissolution may be determined at a temperature of 80°C.

[0098] Suitably, the dissolution may be measured under stirring; for example, at 500 rpm.

[0099] Suitably, the dissolution may be measured by determining conductivity whilst the shaped food or beverage product dissolves in the liquid. The reconstitution time may be provided as the time taken to reach 50%, 60%, 70%, 80%, 90% or 95% of final conductivity. Conductivity may be measured, for example, using a conductivity probe from Metrohm (Switzerland).

[0100] Preferably, the reconstitution time may be provided as the time taken to reach 90% of final conductivity. Suitably, the reconstitution time may be provided as the time taken to reach 90% of final conductivity in 80°C water under stirring at 500 rpm. Suitably, the stirring may be mechanical stirring.

[0101] Suitably, the present shaped powdered food or beverage product may be capable of reconstitution in water such that at least 90% of said shaped powdered food or beverage product is dissolved in less than 240 seconds in deionized water under stirring at 80°C.

[0102] Suitably, the present shaped powdered food or beverage product may be capable of reconstitution in water such that at least 90% of said shaped powdered food or beverage product is dissolved in less than 240, less than 180, less than 120 or less than 60 seconds in deionized water under stirring at 80°C.

[0103] An illustrative method for determining reconstitution time is provided in the present example.

[0104] Porosity

[0105] Suitably, the shaped powdered food or beverage product may have a porosity of 10% to 70%.

[0106] As used herein, ‘porosity’ may refer to a measurement of the void or empty spaces of a material. Suitably, ‘porosity’ may be defined as the ratio between the volume of voids and the total volume of the shaped powdered food or beverage product.

[0107] The porosity of the shaped powdered food or beverage product may comprise open and / or closed pores. ‘Open’ pores (open porosity) may refer to interconnected pores. ‘Closed’ pores (closed porosity) may refer to non-connected cavities.

[0108] Suitably, ‘porosity’ as used herein refers to total porosity and comprises open porosity and closed porosity.

[0109] Suitably, the shaped powdered food or beverage product may have a porosity of 10% to 70%, 15% to 70%, 20% to 70%, 10% to 60%, 10% to 50%, 20% to 70%, 20% to 60%, 20% to 50%, 30% to 70%, 30% to 60%, 30% to 50%, 40% to 70%, or 40% to 60%.

[0110] Suitably, the shaped powdered food or beverage product may have a porosity of at least 10%, at least 20%, at least 30%, or at least 40%. Porosity may be determined using methods which are known in the art. Such methods include, but are not limited to, helium pycnometry, image analysis and water absorption.

[0111] By way of further example, porosity may be determined using an AutoPore IV 9520 (Micromeritics Inc. Norcrose, GA, USA). For example, shape envelop density and matrix density may be determined; and porosity calculated as porosity = 100 (1 -density envelop / density matrix). Illustrative methods for determining porosity are provided in the present Examples.

[0112] A high level of porosity may be advantageous, for example, in enabling desired reconstitution times - as described herein.

[0113] Shaped powdered food or beverage product

[0114] The present shaped powdered food or beverage product may comprise soluble coffee; optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, milk powder, powdered creamer, cocoa powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, malt powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, beverage powder, infant formula powder, fruit powder, powdered food for special medical purpose, soup powder, sauce powder, powdered bouillon, seasoning powder, vegetable powder, protein powder, nutritional powder, powdered food supplement, powdered flavours, powdered probiotic, maltodextrin, vitamin and / or mineral powder powdered prepared meal, carbohydrate powder, polysaccharide powder, a pharmaceutically active powdered ingredient and combination thereof.

[0115] The present shaped powdered food or beverage product may comprise soluble coffee; optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, milk powder, powdered creamer, cocoa powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient.

[0116] The present shaped powdered food or beverage product may comprise malt powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient. The shaped powdered food or beverage product may comprise milk powder.

[0117] The shaped powdered food or beverage product may comprise cocoa powder.

[0118] The shaped powdered food or beverage product may comprise powdered bouillon.

[0119] The product may be provided in a blister packaging, sachet, pouch, bag, canister, bottle, box, or any other suitable closed packaging.

[0120] In one embodiment the shaped powdered food or beverage product is a creamer material. By a creamer material is understood a material useful for adding to a beverage, e.g. a coffee, cocoa or tea beverage, to whiten the beverage, add flavour to the beverage, and / or to produce a foam in the beverage. Creamer materials in liquid or powder form is well known in the art. A creamer material may comprise dairy ingredients such as milk fat, and milk protein, e.g. casein, caseinate, whey protein, whey protein isolate, and / or whey protein concentrate. A creamer material may be a non- dairy creamer comprising non-dairy ingredients such as e.g. vegetable fat, e.g. soybean oil, coconut oil, palm oil, palm kernel oil, com oil, cotton seed oil, canola oil, olive oil, sunflower oil, safflower oil, and / or blends thereof; and / or vegetable protein. A creamer material further often comprises sugar, e.g. sucrose and / or maltodextrin; emulsifiers; stabilisers; flavours; and / or buffer salts. When preparing a sintered creamer material, the first powdered component may e.g. be maltodextrin, and the second powdered component may e.g. be a dried powdered emulsion of fat, protein, emulsifier, and / or buffering salt.

[0121] Suitably, the shaped powdered food or beverage product may be a soluble coffee product. Suitably, the soluble coffee product may be a granulate. In the following the term "granulate" is used to describe a powder product which may be obtainable by agglomeration of smaller powder particles. The granulate particles thus comprise smaller constitutive powder particles. These smaller constitutive powder particles may be partially fused to form the bigger granulate particles.

[0122] The shaped powdered food or beverage product may be suited for foaming instant coffee beverages. It may also be suited for use in foaming instant cappuccino or latte type beverage mixes that are formulated with a foaming creamer powder composition containing e.g. protein. The powdered component for use in the present invention may be, for example, a powdered instant coffee product that has been produced according to traditional methods of spray-drying or freeze-drying of extracts derived from roast and ground coffee. Thus, precursors which have been spray-dried, gas-injected spray-dried, gas-injected extruded, gas-injected freeze-dried, and the like are suitable in the present method. Alternatively, the precursor powder may be spray -frozen particles. Such products and their methods of manufacture are well known to the person skilled in the art.

[0123] Suitably, the powdered component is spray-dried. Suitably, the powdered component comprises instant coffee particles.

[0124] The powdered component may be selected from milk powder, such as e.g. skim milk powder or whole milk powder; soluble coffee powder; coffee creamer, e.g. non-dairy coffee creamer; starch; maltodextrin; flour, e.g. wheat flour; and mixtures thereof.

[0125] The composition of the invention may comprise further ingredients depending on the nature and desired characteristics of the final product. If the final product is a food or beverage product, the composition may contain ingredients such as e.g. sweeteners, e.g. sugar; colorants; flavour; aroma; vitamins; minerals; bulking agents; salts; emulsifiers; stabilisers; free amino acids; nucleic acids; and combinations thereof. Specifically, the composition may comprise additional ingredients that will not take part in the sintering process and thus remain intact in the final product, e.g. ingredients in crystalline form, e.g. sugars, and / or encapsulated ingredients such as encapsulated aroma; encapsulated nutrients, e.g. vitamins and / or minerals; and / or encapsulated bioactive ingredients, e.g. enzymes and / or microorganisms.

[0126] Suitably, the present methods may comprise a further step of at least partially coating the shaped powdered product with a crystalline coating. Accordingly, the present shaped powdered food or beverage product may be at least partially coated with a crystalline coating. Suitable crystalline coatings are described in WO / 2024 / 042154; for example.

[0127] EXAMPLES

[0128] The invention will now be further described by way of examples, which are meant to serve to assist one of ordinary skill in the art in carrying out the invention and are not intended in any way to limit the scope of the invention. Example 1 - Sintering of Maltodextrin powders

[0129] Maltodextrin DE29 or IT29 powders were prepared in cylindrical shapes under different sintering pressures (P), (see Figure la, lb) while maintaining consistent humidity and temperature conditions (see Methods). To investigate the compaction and resistance response of the sintered structure, a compaction test was performed, compressing the sample from the top at a constant rate (see Methods). Before the compaction test, the sintering level was sufficiently strong to prevent the sample from collapsing under its own weight. As the compaction stress (< J) increases, both radial and longitudinal (e) deformations are observed, eventually leading to the breakage of the sample. The strength and fracture pattern of the sample primarily depended on the sintering pressure. Figure 1c shows the stress-strain relationship for 10 samples prepared at 3.5 kPa. Assuming linear deformation before breakage, the Young’s modulus for each sample is computed as E = cr / e (see Fig. Id). It is observed that the Young’ s modulus, rapidly increases to a maximum value at a critical sintering pressure, then, progressively decreased for higher pressures. At higher sintering pressures, the material exhibits characteristics of brittleness, with the breakage pattern consisting of larger fragments compared to those observed at lower sintering pressures.

[0130] A summary of the properties of Maltodextrin DE29 and IT29 cylindrical shapes prepared by sintering methods is shown in Table 1 and Table 2 (parameters for the sintering step - e.g. temperature and pressure are also provided).

[0131] As shown in Table 1 and Table 2, shapes prepared under sintering conditions with an applied pressure achieved advantageous porosity, hardness and reconstitution properties.

[0132] Example 2 - Sintering of creamer powders

[0133] Previous experiments to produce shaped coffee and creamer powders focused on granulation and compaction approaches. Granulation was determined not to be preferable as it resulted in changes to the particle size distributions and colour of the product. Desired reconstitution times were also difficult to achieve. Compaction using a tablet press was also not preferred as it was not possible to achieve shapes with a sufficient hardness and desired reconstitution time.

[0134] Sintering of creamer powders was performed to generate shaped products (see Methods). A summary of the properties of creamer powder shapes prepared by sintering methods is shown in Table 3.

[0135] Methods

[0136] Maltodextrin DE29 / IT29

[0137] Maltodextrin DE29 and IT29 (Roquette, France), are common water-soluble amorphous substances derived from native starch and used in many food applications. The initial powders were characterized by Differential Scanning Calorimetry (TA Instruments Q2000 DSC, 5 °C / min temperature ramp) to extract the onset of the glass transition temperature required to define the sintering temperatures (Tg).

[0138] The moisture of Maltodextrin DE29 and IT29 was 3.98 and 4.02 g / 100g; respectively. Moisture was measured using Thermogravimetric analysis (TGA), measuring weight loss upon heating (2°C / min from 25°C to 180°C) until inflection point.

[0139] Creamer

[0140] A commercial creamer powder was characterized by Differential Scanning Calorimetry to extract the onset of the glass transition temperature required to define the sintering temperatures.

[0141] Cylinder sintering - Maltodextrin / Creamer

[0142] Sintered cylinders were prepared using the following procedure. First, the powder was gently deposited into 16 cylindrical aluminum cavities (each cavity has a radius of 1 cm and a height of 3 cm) at room temperature (25 °C). Excess powder above the cavities was removed with a spatula. A metal cap fitting the cavities, and an additional mass was added on top to adjust target pressure (See Figure 1.a). The entire system was placed in a double-sealed aluminium bag to prevent moisture loss during the sintering process. The bag was then placed in a preheated calibrated oven at a fixed temperature (see Table 1). When the defined sintering time was achieved, the bag was removed from the oven to cool. Cylinders, that had usually retracted by 5% to 20% in diameter depending on the applied pressure, were unmolded carefully and stored in sealed bags before characterization. Hardness - Resistance in compression

[0143] Resistance in compression was measured using a Texture Analyzer HDplusC (Stable Micro Systems) equipped with a 500 kg load cell. Size and diameter of cylinders was first measured before crushing each cylinder vertically using a 3.5cm — wide plate geometry at a constant speed of 0.5 mm / s. The force-distance curve was collected with a time step of 5ms. From the force-distance curves various characteristics such as the maximum breaking force and corresponding distance, or the Young’s modulus and deformation were extracted.

[0144] Reconstitution (Conductivity)

[0145] Reconstitution was measured by a conductivity probe from Metrohm (Switzerland). Samples were dissolved in deionized water under stirring at 20°C or 80°C under stirring at 500 rpm and conductivity was measured over time. The time taken for 90% of the sample to dissolve (t90) was calculated.

[0146] Particle Size Distribution

[0147] Particle Size Distribution (PSD) was measured either by laser diffraction (Malvern Mastersizer 3000 Aero with 2 bars of dispersion pressure) or a Camsizer XT from Retsch Technology (Germany). The technique of digital image analysis is based on the computer processing of a large number of sample’s pictures taken at a frame rate of 277 images / seconds by two different cameras, simultaneously. Characteristic particle size dlO, d50 and d90 were calculated from normalized curves, corresponding to the particle size of 10 %, 50 % and 90 % of the particles respectively.

[0148] Porosity

[0149] Porosity was measured using Micromeritics GeoPyc equipment used to measure shape envelop density. Paar DMA 4500M was used to measured matrix density (extrapolation from liquid solutions) then porosity calculated as: 100 / (1-density envelop / density matrix). Table 1

[0150] Material Shape Sintering Sintering Sintering time Powder particle DSO x Pressure Shape Shape Hardness - type pressure (Pa) temperature size D50 (pm) porosity (%) Maximum stress (°C) at rupture (N / cm2) Maltodextrin DE29 Cylinder 3488 79.2 3 63.8 222527 30.9 1331 Maltodextrin DE29 Cylinder 257 79.2 104 63.8 16399 26.9 588 Maltodextrin DE29 Cylinder 601 79:2 95 63.8 38370 22.3 1119 Maltodextrin DE29 Cylinder 869 79.2 87 63.8 55413 16.8 2113 Maltodextrin DE29 Cylinder 1655 79.2 70 63.8 105562 27.0 1003 Maltodextrin DE29 Cylinder 3488 79.2 46 63.8 222527 36.6 684 Maltodextrin DE29 Cylinder 6105 79.2 31 63.8 389475 34.9 702 Maltodextrin DE29 Cylinder 12981 79.2 16 63.8 828178 38.8 441 Maltodextrin DE29 Cylinder 869 79.2 63.8 55413 47.3 113

[0151]

[0152] 5.4

[0153] Table 2

[0154] Material Shape Sintering Sintering Sintering Powder DSOx Shape Shape Shape Hardness - type pressure temperature time th) particle size Pressure porosity Reconstitution Maximum stress at rc) DSO (pm) (%) time (90 Q20C

[0155] Maltodextrin DE29 Cylinder 257 94.6 63.8 16399 44.0 269 76 Maltodextrin DE29 Cylinder 969 94.6 3 63.8 55413 41.2 195 76 Maltodextrin DE29 Cylinder 1655 94.6 3 63.8 105562 41.2 206 103 Maltodextrin DE29 Cylinder 6105 94.6 3 63.8 389475 41.2 127 132 Maltodextrin DE29 Cylinder 257 94.6 63.8 16399 41.2 370 62 Maltodextrin DE29 Cylinder 869 94.6 3 63.8 55413 41.2 409 472

[0156]

[0157] Maltodextrin DE29 Cylinder 3488 94.6 3 63.8 222527 41.2 270 235 Maltodextrin DE29 Cylinder 6105 94.6 3 63.8 389475 41.2 216 208 Maltodextrin DE29 Cylinder 257 94.6 3 63.8 16399 41.2 / 425 Maltodextrin DE29 Cylinder 257 94.6 3 63.8 16399 41.2 / 1394 Maltodextrin DE29 Cylinder 257 94.6 3 63.8 16399 41.2 / 133 Maltodextrin DE29 Cylinder 6105 94.6 3 63.8 389475 41.2 / 137

[0158] Maltodextrin IT29 Cylinder 3488 79.0 62 182 634796 55.3 47

[0159] Maltodextrin IT29 Cylinder 1655 85.0 16 182 301133 55.3 63 79 Maltodextrin IT29 Cylinder 1655 84.0 16 182 301133 55.3 73 273 Maltodextrin IT29 Cylinder 869 79.0 114 182 158074 55.3 58 50 Maltodextrin IT29 Cylinder 3488 83.7 16 182 634796 55.3 61 204 Maltodextrin IT29 Cylinder 3488 83.5 16 182 634796 55.3 111 234 Maltodextrin IT29 Cylinder 1655 83.7 16 182 301133 55.3 62 115

[0160]

[0161] Table 3

[0162] Material Shape Sintering Sintering Sintering Powder DSOx Shape Shape Shape Hardness - type pressure temperature time (h) partide size Pressure porosity Reconstitution Maximum stress (Pa) (°Q D50 (μm) (%) time t90 at rupture (N / cm2)

[0163] @80°C(s)

[0164] Creamer Cylinder 257 65 72 258 66314 55.3 14.2 32

[0165] Creamer Cylinder 257 70 72 258 66314 55.3 18.4 43

[0166] Creamer Cylinder

[0167]

[0168] 257 75 72 258 66314 51.2 91.6 144

Claims

1. CLAIMS1. A method of making a shaped powdered food or beverage product; the method comprising:3.(a) providing a powdered component; and4.(b) forming the powdered component into a desired shape to form a shaped powdered food or beverage product;5.wherein step (b) is performed by applying a compaction pressure of from 50 to 30,000 Pa while sintering the powdered component.

2. The method according to claim 1, wherein a compaction pressure of from 50 to 10,000 Pa is applied in step (b).

3. The method according to claim 1 or 2, wherein a compaction pressure of from 100 to 3,000 Pa is applied in step (b).

4. The method according to any preceding claim, wherein the compaction pressure in step (b) is applied as a uniaxial load; preferably wherein the uniaxial load in step (b) is applied as a vertical force with lateral restriction.

5. The method according to any preceding claim wherein the powdered component has an average particle diameter of from 1 pm to 2500 pm, preferably from 20 pm to 1000 pm, more preferably from 60 pm to 1000 pm.

6. The method according to any preceding claim wherein the product of the compaction pressure (P, pascal) and average particle diameter of the powdered component particles (d, pm) is from 7,000 to 900,000, preferably from 30,000 to 300,000.

7. The method according to any preceding claim wherein the sintering is performed by (i) heating the powdered component to a temperature of 30°C to 100°C, preferably 40°C to 70°C; and / or (ii) wherein the sintering is performed by heating the powdered component to a temperature of 1°C to 70°C above the glass transition temperature (Tg) of the powdered component, preferably 1°C to 40°C above the Tgof the powdered component, wherein:12.- the Tgof the powdered component is the Tgof the overall powdered component, when the powdered component is made of plurality of components with the same Tgor made of the same component, - the Tg of the powdered component is the Tg of the component with the lowest Tg, when the powdered component is made of plurality of components with different Tg.

8. The method according to any preceding claim wherein the food or beverage product is suitable for reconstitution in a liquid to provide a food or beverage composition9. The method according to claim 8 wherein the shaped powdered product is capable of reconstitution in water such that at least 90% of the product is dissolved in less than 240 seconds, preferably less than 60 seconds, in deionized water under stirring at 80°C.

10. The method according to any preceding claim wherein the shaped powdered product has a porosity of 10 to 70%.

11. The method according to any preceding claim wherein at least 30%, preferably at least 40%, more preferably at least 50%of the powdered component is amorphous.

12. The method according to any preceding claim wherein the powdered component comprises soluble coffee - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, milk powder, powdered creamer, cocoa powder -optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, malt powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, beverage powder, infant formula powder, fruit powder, powdered food for special medical purpose, soup powder, sauce powder, powdered bouillon, seasoning powder, vegetable powder, protein powder, nutritional powder, powdered food supplement, powdered flavours, powdered probiotic, maltodextrin, vitamin and / or mineral powder, powdered prepared meal, carbohydrate powder, polysaccharide powder, a pharmaceutically active powdered ingredient and combination thereof.

13. A shaped powdered product obtainable by the method of any of claims 1 to 12.

14. A shaped powdered food or beverage product which has a porosity of 10 to 70% and a hardness from 30 to 4000 N / cm2, preferably from 100 to 2500 N / cm2.

15. A shaped powdered food or beverage product according to claim 14 which is capable of reconstitution in water such that at least 90% of the product is dissolved in less than 240, preferably less than 60, seconds in deionized water under stirring at 80°C.

16. A shaped powdered food or beverage product according to any of claims 13 to 15 which comprises soluble coffee; optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, milk powder, powdered creamer, cocoa powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, malt powder - optionally further comprising powdered carbohydrate, a powdered flavour and / or a powdered milk ingredient, beverage powder, infant formula powder, fruit powder, powdered food for special medical purpose, soup powder, sauce powder, powdered bouillon, seasoning powder, vegetable powder, protein powder, nutritional powder, powdered food supplement, powdered flavours, powdered probiotic, maltodextrin, vitamin and / or mineral powder powdered prepared meal, carbohydrate powder, polysaccharide powder, a pharmaceutically active powdered ingredient and combination thereof.

Images