Instant Coffee Sintering with Gas Flow for Crema Formation
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Solution Overview
Problem
Instant soluble coffee products typically lack a desirable foamed upper surface, known as 'crema,' which is associated with traditional roast and ground coffee, due to structural collapse of microstructure during agglomeration processes like sintering, resulting in insufficient or coarse foam formation.
Innovation Solution
A method involving sintering a porous particulate base powder with a particle porosity of at least 45% and pore diameters less than 80 micrometres, while forcing gas through the powder layer, to form a sintered cake with controlled porosity and structure that retains gas, enhancing crema formation upon reconstitution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional sintering or agglomeration processes are used to produce instant soluble coffee powder, then the product is readily soluble in water, but the microstructure collapses resulting in insufficient or coarse foam formation
Solution Approach 1:
The patent applies parameter changes by carefully controlling sintering temperature (below glass transition temperature), humidity (50-80% relative humidity), and time parameters to prevent microstructure collapse while achieving particle bonding. This resolves the contradiction by finding optimal parameter ranges that maintain both solubility and foam-forming microstructure.
Solution Approach 2:
The patent utilizes porous materials by maintaining the porous structure of the base powder throughout the sintering process. The porous microstructure is preserved through controlled sintering conditions, enabling the product to trap gas and form fine foam upon reconstitution with water, thus resolving the contradiction between solubility and foam formation.
2Strength
If external compaction is applied during sintering to form a sintered mass, then the product gains structural integrity, but the internal pores collapse resulting in loss of foaming capability
Solution Approach 1:
The patent applies partial action by using only sufficient compaction pressure during sintering to achieve particle bonding without excessive pressure that would collapse pores. The sintering process provides just enough mechanical strength while preserving the porous structure needed for foaming, resolving the contradiction between structural integrity and foam volume.
Solution Approach 2:
The patent changes the parameter of compaction pressure to a low level during sintering, combined with controlled temperature and humidity parameters, to achieve structural integrity without pore collapse. This parameter optimization resolves the contradiction between strength and foaming capability.
3Manufacturing precision
If gas is forced through the powder layer during sintering to maintain porosity, then the microstructure is preserved for foam formation, but the process complexity increases
Solution Approach 1:
The patent applies self-service by allowing the porous structure to maintain itself through controlled gas flow during sintering. The gas flow regime is controlled to prevent pore collapse without requiring complex external structuring, thus achieving porosity control with moderate process complexity.
Solution Approach 2:
The patent uses pneumatic control by forcing gas through the powder layer during sintering to maintain porosity and prevent microstructure collapse. This pneumatic approach provides simple control over the sintering process while preserving the foam-forming microstructure, resolving the contradiction between porosity control and process complexity.
4Strength
If the sintering temperature is increased to improve particle bonding, then the product strength increases, but the porous structure collapses resulting in coarse foam
Solution Approach 1:
The patent changes the temperature parameter to be below the glass transition temperature of the material, combined with controlled humidity and time parameters, to achieve sufficient particle bonding without pore structure collapse. This multi-parameter optimization resolves the contradiction between strength and pore structure preservation.
Solution Approach 2:
The patent creates a composite effect by combining controlled temperature, humidity, and gas flow parameters during sintering to achieve both particle bonding and pore structure preservation simultaneously. This composite approach resolves the contradiction between strength and pore structure.
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 method produces an instant coffee product with a foamed upper surface similar to traditional coffee, maintaining the desired porosity and structure to achieve a high volume of crema, improving the mouthfeel and aroma retention of the beverage.
Implementation Method 1
sintering a layer of said powder for a period of between 2 s and 600 s while gas is forced through the layer
Implementation Method 2
sintering a layer of said powder for a period of between 2 s and 600 s while gas is forced through the layer, to form a sintered cake
Implementation Method 3
the porous base powder is characterised in that it has a particle porosity of at least 45%, wherein the pores have a D50 diameter of less than 80 micrometres
Data Source
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AI summary
The present invention relates to a method for producing an instant beverage product with good foaming and/or dissolution properties, wherein a layer of porous base powder is sintered while gas is forced through the layer.