Coffee Tablet Hardness and Disintegration via Multi-Step Compaction
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Solution Overview
Problem
Consumers face difficulties in determining the correct dose of coffee for brewing pots of different sizes and in adjusting the strength of brewed coffee with existing coffee products, which are limited in versatility and compatibility with automatic drip coffee makers.
Innovation Solution
Development of coffee tablets made through a multi-step compaction process that ensures a hardness of at least 30 N and friability of no greater than 10%, allowing them to disintegrate readily in automatic drip coffee makers, with compositions including at least 91% ground roast coffee and optional additives for improved mechanical properties and flavor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If single serving pods are used, then the correct dose for single serving is provided, but they must have a specific configuration to fit particular brewers and are limited to making single cups
Solution Approach 1:
The coffee tablets are designed to be universally compatible with automatic drip coffee makers of various sizes (single cup, 4-cup, 12-cup brewers) while maintaining precise dosing. The tablets can be used individually for single servings or multiple tablets can be combined for larger batches, providing both dose accuracy and brewing versatility.
Solution Approach 2:
The coffee product is segmented into individual tablets, each containing a precise dose of ground roast coffee. This segmentation allows consumers to use exactly the number of tablets needed for their desired serving size, providing both precise dosing control and flexibility for different brew volumes.
2Measurement precision
If filter packs with predetermined coffee amounts are used, then standardized doses are provided, but the consumer is required to make the amount of servings for which the filter pack is designed and cannot change the strength
Solution Approach 1:
The system transitions from static filter packs with fixed serving requirements to dynamic tablet-based brewing where the number of tablets can be adjusted based on desired serving size and strength. This allows the brewing process to be dynamically adapted to consumer preferences while maintaining standardized dosing in each tablet.
Solution Approach 2:
By segmenting the coffee into individual tablets rather than requiring use of entire filter packs, consumers can selectively use the precise number of tablets needed for their desired serving size, providing both dose standardization and serving flexibility.
3Ease of operation
If ground roast coffee is compacted into tablets, then dosing convenience is improved, but the tablets must have sufficient hardness for handling while disintegrating readily during brewing
Solution Approach 1:
The compaction process parameters (pressure, duration, temperature) are optimized to achieve the desired balance between tablet hardness for handling and disintegration performance during brewing. The ground roast coffee is compacted under controlled conditions to create tablets with sufficient structural integrity for handling but porosity and bonding characteristics that allow rapid disintegration when exposed to brewing water.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coffee tablets provide a convenient, versatile solution for brewing the right amount of coffee with adjustable strength, offering improved brewing efficiency and compatibility with automatic drip coffee makers, while maintaining high coffee quality and ease of use.
Implementation Method 1
a first exemplary coffee tablet is made by a multi-step compaction process in which at least a first compression and a separate second compression are carried out in the same compaction die
Implementation Method 2
a pre-compression step is carried out at a lower compaction force but in the same compaction die as the main compression step
Implementation Method 3
readily disintegrates when contacted with hot water during brewing in an automatic drip coffee maker
Implementation Method 4
readily disintegrates when contacted with hot water during brewing
Data Source
AI summary
A ground roast coffee tablet which is capable of being brewed in a conventional automatic drip coffee maker, and which exhibits sufficient strength to withstand all aspects of manufacture, handling, packaging, transport without breakage but also readily disintegrates when contacted with hot water during brewing. The tablet comprises at least about 91% ground roast coffee, has a density of at least 0.90 g/cm3, has a hardness of at least about 30 N and has a friability of no greater than about 10%.