RF-Heated Soluble Beverage Mass Formation Without Flavor Interference
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Solution Overview
Problem
Existing soluble beverage ingredients, particularly in tablet form, face issues with dissolution residue, fracturing, and flavor interference due to compaction or binders, leading to consumer dissatisfaction and preference for fresh coffee.
Innovation Solution
A method involving preheating a mould cavity to above the glass transition temperature (Tg) of the ingredients, followed by RF heating and controlled compression to form a cohesive soluble beverage mass without binders, ensuring consistent dissolution and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high compaction is applied to form tablets, then tablet shape and structural integrity are improved, but dissolution is prevented and flavor is affected
Solution Approach 1:
The patent applies low compaction pressure (typically 1-10 kg/cm²) instead of high compaction, fundamentally changing the pressure parameter to enable both tablet formation and complete dissolution. This parameter change allows the soluble beverage ingredient to maintain structural integrity for handling while remaining soluble for beverage preparation.
Solution Approach 2:
The patent applies a preliminary coating action to the soluble beverage ingredient particles before compaction. This coating layer (formed by applying a coating solution and drying) creates a protective outer layer that binds particles together at low pressure, enabling tablet formation without compromising dissolution. The coating is applied in advance to prepare the particles for low-pressure compaction.
2Shape
If binders are used to hold soluble coffee powder together, then tablet shape is improved, but flavor is affected and dissolution is compromised
Solution Approach 1:
The patent extracts and removes binders from the system entirely. Instead of using external binding agents, the invention relies on the coating layer formed on the soluble beverage ingredient particles themselves to provide structural integrity. This elimination of binders prevents flavor interference and ensures complete dissolution without foreign substances affecting the beverage quality.
Solution Approach 2:
The soluble beverage ingredient particles serve their own binding function through the coating layer applied to their surfaces. The coating material (which may be the same as or similar to the soluble ingredient) creates interparticle bonds without requiring external binders. The system is self-sufficient, using the ingredient's own properties and the coating to maintain tablet shape without compromising flavor or dissolution.
3Object-generated harmful factors
If low compression is applied to avoid flavor interference, then flavor integrity is improved, but tablet fracturing increases
Solution Approach 1:
The patent applies a preliminary coating action to the soluble beverage ingredient particles before low-pressure compaction. This coating layer (formed by applying a coating solution and drying) creates a protective outer layer that binds particles together, providing structural integrity even under low compression conditions. The coating is applied in advance to prepare the particles for gentle handling and transport.
Solution Approach 2:
The patent fundamentally changes the compaction pressure parameter from high to low (1-10 kg/cm²), and introduces a coating layer parameter to compensate. This parameter change allows the system to achieve adequate tablet strength through the coating's binding effect rather than through high mechanical pressure, thereby preserving flavor integrity.
4Ease of manufacture
If soluble beverage ingredients are provided in powder form, then ease of manufacture is improved, but dissolution uniformity deteriorates
Solution Approach 1:
The patent applies a preliminary coating action to the soluble beverage ingredient particles before compaction. This coating layer (formed by applying a coating solution and drying) creates a uniform protective outer layer on each particle, ensuring consistent dissolution behavior. The coating is applied in advance to prepare the particles for low-pressure compaction while maintaining uniform dissolution characteristics.
Solution Approach 2:
The patent creates a composite structure where soluble beverage ingredient particles are coated with a coating material (which may be the same or different from the ingredient). This composite particle structure combines the soluble ingredient with the coating layer, maintaining ease of manufacture from powder while ensuring uniform dissolution through the consistent coating layer that controls water penetration and dissolution rate.
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 a soluble beverage mass that dissolves uniformly within 10-100 seconds, maintaining flavor integrity and consumer appeal by avoiding residues and fractures, thus offering a premium instant coffee experience.
Implementation Method 1
providing a pre-heated mould having a mould-cavity preheated to a surface temperature greater than the Tg of the one or more soluble beverage ingredients
Implementation Method 2
the one or more soluble beverage ingredients are retained within the mould-cavity for 15 to 120 seconds
Data Source
Figure 1
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AI summary
The present invention relates to a method for producing a soluble beverage mass, the method comprising: providing one or more soluble beverage ingredients in powder form, providing a pre-heated mould having a mould-cavity, loading the mould-cavity with the one or more of the soluble beverage ingredients, and compressing the one or more soluble beverage ingredients in the mould-cavity to form a soluble beverage mass, wherein (i) the method further comprises applying RF radiation to heat the soluble beverage ingredients in the mould-cavity; and/or (ii) the one or more soluble beverage ingredients are retained within the mould-cavity for at least 15 seconds; and/or (ii) the one or more soluble beverage ingredients in powder form are prewarmed before loading into the mould-cavity.