System and method for highly uniform production of cold-brewed beverages having extended shelf-life
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Solution Overview
Problem
Current cold-brewing methods lack batch-to-batch consistency in organoleptic and nutritive properties, and fail to extend the shelf-life of cold-brewed beverages due to variations in temperature, extraction rate, and residual oxygen, which poses economic and safety concerns.
Innovation Solution
A method involving agitation in a brewing chamber with a non-oxygen gas mixture comprising hydrogen to maintain even particulate suspension, followed by two-phase filtration and packaging under oxygen-free conditions, ensuring consistent flavor, texture, and extended shelf-life of up to 12 months.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carb-stoning (gasification with pressurized non-oxygen gas) is used for effervescence and stability, then oxygen is purged from the beverage, but batch-to-batch consistency in organoleptic and nutritive properties deteriorates due to variations in temperature, extraction rate, and total dissolved solids
Solution Approach 1:
The patent applies parameter changes by precisely controlling temperature, pressure, and gas composition throughout the brewing and conditioning processes. Specific parameters include maintaining brewing temperatures between 40-70°F, using non-oxygen gases with specific oxygen content thresholds (<1000 ppm, preferably <100 ppm), and controlling extraction times. These controlled parameter changes ensure consistent organoleptic and nutritive properties across batches while maintaining stability.
Solution Approach 2:
The patent implements feedback mechanisms through continuous monitoring and adjustment of process variables. Total dissolved solids (TDS) measurements are used to adjust extraction parameters, oxygen levels are monitored to control gasification timing and intensity, and temperature is continuously regulated. This feedback ensures both stability and batch-to-batch consistency by correcting deviations in real-time.
2Object-generated harmful factors
If agitation is eliminated during product-conditioning phases to reduce solid particulate matter through gravity separation, then particulate matter is reduced, but even particulate suspension and evenly blended immiscible oils and alcohols cannot be achieved without emulsifiers
Solution Approach 1:
The patent applies dynamics by implementing a multi-phase conditioning process with varying agitation levels. Initial vigorous agitation ensures complete dissolution and uniform distribution of solids and immiscible components. This is followed by reduced agitation or gravity separation phases to allow particulate settling. The dynamic adjustment of agitation intensity throughout the conditioning process achieves both uniform suspension and reduced particulate matter without requiring emulsifiers.
3Reliability
If low temperatures are used in cold-brew processes to preserve flavor, then organoleptic quality is maintained, but bacteria are not killed and shelf-life is limited
Solution Approach 1:
The patent introduces non-oxygen gases (nitrogen, carbon dioxide, or argon) as intermediary protective agents. These gases create an oxygen-free atmosphere during brewing, conditioning, and packaging, preventing oxidative degradation and inhibiting aerobic bacterial growth. This intermediary protective environment allows the beverage to maintain organoleptic quality at low temperatures while extending shelf-life without requiring pasteurization or refrigeration throughout the supply chain.
Solution Approach 2:
The patent creates an inert atmosphere using non-oxygen gases with specific properties (oxygen content <1000 ppm, preferably <100 ppm). This inert environment is maintained throughout the entire process from brewing through packaging and storage. The inert atmosphere prevents oxidation and inhibits microbial growth, enabling extended shelf-life while preserving flavor, aroma, and other organoleptic qualities at cold temperatures.
4Duration of action of stationary object
If post-brew acidification and/or pasteurization are used to extend shelf-life, then bacteria are eliminated, but off-flavors are introduced and nuanced flavors are degraded
Solution Approach 1:
The patent applies preliminary action by eliminating oxygen from the system before brewing begins and maintaining an oxygen-free environment throughout the entire process. Non-oxygen gases are introduced into the brewing chamber, transfer lines, and packaging containers prior to beverage processing. This preliminary creation of an inert atmosphere prevents oxidative degradation and inhibits bacterial growth from the outset, extending shelf-life without requiring post-brew acidification or pasteurization that would compromise flavor quality.
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 achieves consistent organoleptic and nutritional qualities with significantly extended shelf-life, reducing batch-to-batch variations and ensuring safety by eliminating residual oxygen and bacteria, thereby enhancing product stability and consumer safety.
Implementation Method 1
mixing the filtered aqueous coffee extract in the purged conditioning chamber in the presence of the non-oxygen gas comprising hydrogen, using agitation sufficient to maintain an even or substantially even suspension of dissolved and undissolved solids, at a temperature and for a time sufficient to eliminate or substantially eliminate any remaining dissolved oxygen present in the filtered aqueous coffee extract
Data Source
AI summary
Provided are surprisingly effective methods for producing uniform, cold-brew beverages (e.g., coffee, tea, fruit juice/extract, vegetable juice/extract, etc.) having an extended shelf-life, comprising: use of non-oxygen gas mixtures comprising hydrogen (to reduce or eliminate total packaged oxygen (TPO)), use of pressure/vacuum ports in brewing and/or conditioning chambers to provide chambered vacuum and/or pressure to enhance oxygen elimination, use of continuous mixing/agitation during the final conditioning phase to provide for even particulate suspension, use of a two-phase filtration system to provide for uniform tailoring of the amount and/or size of undissolved solids, and use of jacketed brewing and/or conditioning chambers for enhanced control of temperature, extraction uniformity and conditioning. Cold-brew beverages prepared by the methods, and systems for making same are provided. Beverages prepared by any method and packaged in a container and exposed therein to a non-oxygen gas mixture comprising hydrogen, and methods for making same are provided.