System for producing a cold brew extract
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Solution Overview
Problem
Conventional cold brew coffee production methods are time-consuming, difficult to scale commercially, and pose food safety challenges due to open systems requiring chemical sanitation, resulting in inefficient extraction times and inconsistent product quality.
Innovation Solution
A closed system with an extraction tank using a high-pressure pump to circulate water through the raw material, incorporating back pressure control and gas introduction to enhance turbulence and extraction efficiency, along with a sealed design for easier sanitation and higher extract concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cold brew process is used with open system, then extraction can take place, but extraction time is too long (16-20 hours) and sanitation is difficult
Solution Approach 1:
The patent applies hydraulic principles by using pressurized water circulation through the coffee grounds. A pump forces water through the bed of grounds at controlled pressure and flow rates, dramatically accelerating extraction from 16-20 hours to minutes while maintaining extraction quality through controlled hydraulic parameters.
Solution Approach 2:
The system employs periodic circulation of water through the coffee grounds, with the pump cycling water flow through the extraction bed. This periodic action enhances mass transfer and prevents channeling, improving extraction efficiency and reducing required time while maintaining consistency.
2Reliability
If conventional cold brew process is used, then extraction takes place, but system is open and requires chemical sanitation
Solution Approach 1:
The patent implements a closed system that can be purged with inert gas (nitrogen or carbon dioxide) to create an oxygen-free environment. This prevents microbial growth and oxidation, ensuring food safety without requiring chemical sanitation, while the closed design allows for easy sanitization through steam or chemical rinsing of internal surfaces.
Solution Approach 2:
The system uses sealed containers and tubing that form a closed environment, isolating the coffee extraction process from external contamination. These flexible or rigid enclosures can be easily disassembled and sanitized, replacing the open system that required complex chemical sanitation procedures.
3Quantity of substance
If conventional cold brew process is used, then extraction occurs, but extract concentration is low (2.5% TDS) requiring large mixing ratios
Solution Approach 1:
The patent changes key parameters including water pressure, flow rate, and circulation time to optimize extraction efficiency. By controlling these parameters, the system achieves higher extract concentrations (exceeding 2.5% TDS) that reduce the water-to-concentrate mixing ratio needed by consumers, improving both product quality and production efficiency.
Solution Approach 2:
The system continuously circulates water through the coffee grounds during extraction, maintaining constant contact between water and grounds. This continuous action maximizes mass transfer and extraction efficiency, producing higher concentration extract in less time compared to batch methods.
4Loss of time
If high pressure pump is used to accelerate extraction, then extraction time is reduced, but system complexity increases
Solution Approach 1:
The pump serves multiple functions: it pressurizes water for accelerated extraction, circulates water through the grounds, and can be integrated with the closed system for sanitation operations. This multi-functionality reduces overall system complexity despite the addition of pressurization capability.
Solution Approach 2:
The patent combines the extraction, filtration, and sanitation functions into an integrated closed system. The pump, pressure vessel, and filtration components work together as a unified system that achieves accelerated extraction while simplifying sanitation through the closed design, offsetting the complexity of adding pressurization.
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 system achieves accelerated extraction in approximately 45 minutes, producing a higher concentration of cold brew extract with improved uniformity and taste profile, while reducing production time and labor costs, and ensuring sanitary conditions.
Implementation Method 1
A pump is cooperative with the water inlet so as to pump water under pressure through the water inlet such that the water flows through the raw material in the extraction tank
Implementation Method 2
A back pressure control valve is in cooperation with the extract outlet so as to control water pressure within the extraction tank
Data Source
AI summary
A system and a method for producing a cold brew extract are provided. The system and method include the use of an extraction tank adapted to receive raw material such as ground coffee beans therein. Water is pumped into the extraction tank. A back pressure control valve is provided so as to pulse the back pressure within the tank. This pulsed back pressure increases turbulence within the tank. Combined with the flow rate and pressure within the tank, the turbulence allows for cold brewed extract concentrate to be produced in a much quicker time than associated with prior art methods. A number of extraction tanks may be provided in the system of the present invention so as to increase yield. A gas may be introduced in line with the pumped water.