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Title:
BEVERAGE MASS AND A METHOD FOR THE MANUFACTURE THEREOF
Document Type and Number:
WIPO Patent Application WO/2016/091943
Kind Code:
A1
Abstract:
The present invention relates to a method for producing a soluble beverage mass, the method comprising: i. providing one or more soluble beverage ingredients in powder form, ii. providing a pre-heated mould having a mould-cavity, iii. loading the mould-cavity with a first portion of the one or more of the soluble beverage ingredients, iv. loading the mould-cavity with one or more discrete inclusions, v. loading the mould-cavity with a second portion of the one or more of the soluble beverage ingredients, vi. compressing the contents of the mould-cavity to form a soluble beverage mass.

Inventors:
DIMOULA MYRTO (GB)
ZIER MAXI (DE)
KANG WON CHEAL (GB)
Application Number:
PCT/EP2015/079105
Publication Date:
June 16, 2016
Filing Date:
December 09, 2015
Export Citation:
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Assignee:
KONINKL DOUWE EGBERTS BV (NL)
International Classes:
A23G1/56; A23F5/38; A23G1/20; A23L2/395
Domestic Patent References:
WO2011063322A12011-05-26
WO2008113778A12008-09-25
WO2013001052A12013-01-03
WO2014207557A22014-12-31
Foreign References:
US3293041A1966-12-20
EP1906745A12008-04-09
GB2499496A2013-08-21
Attorney, Agent or Firm:
BOULT WADE TENNANT (70 Gray's Inn Road, London Greater London WC1X 8BT, GB)
Download PDF:
Claims:
Claims:

1 . A method for producing a soluble beverage mass, the method comprising:

i. providing one or more soluble beverage ingredients in powder form,

ii. providing a pre-heated mould having a mould-cavity,

iii. loading the mould-cavity with a first portion of the one or more of the soluble beverage ingredients,

iv. loading the mould-cavity with one or more discrete inclusions,

v. loading the mould-cavity with a second portion of the one or more of the soluble beverage ingredients,

vi. compressing the contents of the mould-cavity to form a soluble beverage mass.

2. The method according to claim 1 , wherein the soluble beverage mass has a weight of from 2 to 20g.

3. The method according to claim 1 or claim 2, wherein the one or more discrete inclusions have a mean longest diameter of from 0.05cm to 2cm.

4. The method according any of the preceding claims, wherein the ratio of the first and second portions of the one or more soluble beverage ingredients is from 2:1 to 1 :2, preferably about 1 :1 .

5. The method according to any of the preceding claims, wherein the discrete inclusions are loaded into the mould cavity in a pre-prepared mixture with a third portion of the one or more soluble beverage ingredients.

6. The method according to claim 5, wherein the ratio of the first and second portions to the third portion of the one or more soluble beverage ingredients is from 2:1 to 10:1 . 7. The method according to any of the preceding claims, wherein the discrete inclusions are selected from marshmallows, chocolate pieces, popping candy, rice puffs, chocolate beans, jelly babies, sugar balls, dried fruit, choco pops, corn flakes, sugar covered chocolate beans, gum pieces, encapsulated syrups and flavourings, honeycomb, nuts, jelly beans and honey loops. 8. The method according to any of the preceding claims, wherein the contents of the mould- cavity are compressed at a pressure of from 0.5 to 1 MPa, preferably about 0.65 MPa.

9. The method according to any of the preceding claims, wherein the one or more soluble beverage ingredients are retained within the mould-cavity for at least 30 seconds, preferably from 45 to 150 seconds.

10. The method according to any of the preceding claims, wherein the one or more soluble beverage ingredients are compressed within the mould-cavity for at least 30 seconds, preferably from 45 to 120 seconds. 1 1 . The method according to any of the preceding claims, wherein compression is provided by a preheated closure for the mould-cavity.

12. The method according to any of the preceding claims, wherein the mould and/or closure is preheated to a surface temperature greater than the Tg of the one or more soluble beverage ingredients.

13. The method according to any of the preceding claims, wherein the mould and/or closure is heated to a temperature of from 80 to 120°C. 14. The method according to any of the preceding claims, wherein the step of compressing reduces the volume of the mould contents by from 10 to 50% of the initial volume.

15. The method according to any of the preceding claims, wherein the one or more soluble beverage ingredients in powder form are prewarmed before loading into the mould-cavity.

16. The method according to any of the preceding claims, wherein the one or more soluble beverage ingredients comprises soluble coffee, creamer, milk solids, sugar, flavourings, colourings, cocoa or chocolate, or a mixture of two or more thereof. 17. The method according to any of the preceding claims, wherein the soluble beverage ingredients in the mould-cavity are not subjected to RF heating; and/or do not comprise a binder.

18. The method according to any of the preceding claims, wherein the inclusions form from

10 to 90wt% of the total beverage mass, preferably from 40 to 60wt% and most preferably about 50wt%.

19. A soluble beverage mass obtainable by the method of any of the preceding claims.

20. A soluble beverage mass comprising one or more soluble beverage ingredients and having a weight of from 2 to 20g, the soluble beverage mass having a density of from 0.5g/cm3 to 1 .7g/cm3, and a surface hardness breaking force of at least 10N, and containing one or more discrete inclusions having a mean longest diameter of from 0.05cm to 2cm.

21 . A method of preparing a beverage, the method comprising contacting the soluble beverage mass of claim 19 or claim 20, or produced according to the method of any of claims 1 to 18, with an aqueous medium.

22. A beverage preparation system for preparing a coffee beverage according to claim 20, the system comprising means for providing an aqueous beverage medium to the soluble beverage mass of claim 19 or claim 20, or produced according to the method of any of claims 1 to 18, to dispense a beverage from the system.

23. A method for producing a soluble beverage mass, the method comprising:

i. providing one or more soluble beverage ingredients in powder form,

ii. providing a pre-heated mould having a mould-cavity,

iii. providing one or more discrete inclusions,

iv. loading the mould-cavity with the one or more of the soluble beverage ingredients and the one or more discrete inclusions,

v. compressing the contents of the mould-cavity to form a soluble beverage mass.

24. The method according to claim 23, wherein in the step of loading the mould-cavity, the one or more of the soluble beverage ingredients are loaded into the mould cavity before or after the one or more discrete inclusions.

Description:
Beverage Mass and a Method for the Manufacture thereof

This disclosure relates to soluble beverage masses and a method of producing them. In particular, the disclosure relates to soluble beverage masses with discrete inclusions for producing beverages such as instant coffee or hot chocolate with, for example, marshmallows.

There has developed a considerable market for consumers who wish to prepare beverages at home to replicate the beverages available in cafes and restaurants. While a number of approaches to providing these drinks require the use of a beverage preparation machine, such as a cartridge- or pad-using system, it is more convenient for consumers to use instant or soluble beverage ingredients, such as freeze-dried coffee granules.

While ingredients such as soluble coffee granules have a number of advantages, such as allowing fine-tuning of the beverage strength, it also provides an opportunity for significant variance in the final beverage quality.

To prepare luxury beverages, such as creamy hot chocolate, or a complex multi-part beverage, such a hot chocolate with marshmallows, it has typically been necessary to provide a consumer with a kit. For example, the kit might contain a first package of a hot chocolate powder and a second package of the marshmallows.

One approach to provide a simpler provision of luxury beverages has been contemplated in WO20081 13778, which low density sintered body containing materials such as dried fruit, marshmallows and croutons. This ensures that each beverage produced is identical and of the high quality intended by the beverage ingredient manufacturer.

However, the provision of ingredients in tablet form has not yet been perfected. WO20081 13778 teaches that these materials could not be formed into a beverage tablet by tablet-pressing as their structure would be destroyed. However, for tablets prepared with low compression and/or without the use of a suitable binder, there is a further risk of damage or fracturing of the tablet. If the consumer opens a tube of tablets and finds that they are chipped or broken, then the impression of quality is significantly diminished.

WO2007009600 describes blocks for use in preparing beverages which contain inclusions such as leaves and fruit. The inclusion may be any suitable insoluble entity that adds to the interest, excitement and/or enjoyment of the finished beverage. It may, for example, be a confectionery piece such as a gelled sweet. The method of making the beverage precursor block involves drying an aqueous mixture of plant extract and inclusions. WO2007009600 states that the compression forces involved in the manufacture of the tablets would necessarily disintegrate most inclusions. US3293041 describes a method for the manufacture of highly-soluble self-supporting tablets. These tablets are small 1 g pellets of soluble coffee or tea, and are prepared by compression in a heat-treatment zone of a pelletiser. The pellets are quickly produced (2 to 3 seconds) using high temperatures (1 18 to 150°C) and low pressures (13kPa to 28kPa) and the final product dissolves completely in 2 to 6 seconds. As a results of the manufacturing process, the pellets are low density with a protective outer crust. However, such tablets do not provide a desirable multicomponent final beverage.

EP1768502 provides large confectionary products which contain inclusions.

GB2515486 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 having a contact surface, loading the mould-cavity with the one or more of the soluble beverage ingredients, applying RF radiation to heat the soluble beverage ingredients in the mould-cavity, and compressing the one or more heated soluble beverage ingredients in the mould-cavity to form a soluble beverage mass. Also disclosed is apparatus for the manufacture of the beverage mass.

EP0324072 discloses a beverage capsule in which a beverage base is enclosed in a thin walled solid envelope made of chocolate or a fat-based confectionery coating.

FR2644679 discloses a casing made in a mould having a core of which the cavity will be filled with one or more food components in a filling-compacting cycle. The cavity will be closed off by a glazing-type method closing off the food core inside. The method according to the invention is intended particularly for the preparation of beverages.

FR2086669 discloses a cube comprising a lump of sugar inside which there is a concentrated soluble drink product, such as milk, coffee, tea or chocolate. Pref. the concentrated drink product is in the form of a powder and is accommodated in a cavity inside the sugar lump.

W099/25879 discloses a process for association of additives such as flavours, essences, extracts, essential oils to natural sweeteners like saccharose and artificial sweeteners, especially in individual portions in the form of lumps or powder. Accordingly, it is desirable to provide a new form for beverage ingredients suitable for providing complex beverages and a method for making them and/or to tackle at least some of the problems associated with the prior art or, at least, to provide a commercially useful alternative thereto. Accordingly, in a first aspect the present disclosure provides 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 a first portion of the one or more of the soluble beverage ingredients,

loading the mould-cavity with one or more discrete inclusions,

loading the mould-cavity with a second portion of the one or more of the soluble beverage ingredients,

compressing the contents of the mould-cavity to form a soluble beverage mass. Preferably the one or more discrete inclusions have a mean longest diameter of from 0.05cm to 2cm.

The present invention will now be further described. In the following passages different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.

The present inventors have found a new method for producing soluble beverage masses:

discrete bodies of ingredients suitable for forming beverages. By the term "soluble beverage mass" it is meant a discrete body formed from ingredients which are themselves fully soluble in a beverage medium and which serve to provide said medium with the flavour and consistency of a desired beverage. It should be understood that a soluble beverage mass is intended to cover, for example, tablets, lozenges and balls having a specifically determined shape and size. It is not intended to cover, for example, loose powders of beverage ingredients such as freeze-dried coffee or milk powders. Obviously, the soluble beverage mass is in a substantially dry, not-yet dissolved form suitable for dissolution. Preferably the masses are provided in sealed air and moisture tight containers. The soluble beverage ingredients which form the mass may contain a minority of insoluble material. For example, finely ground roasted coffee may be included to provide a unique mouthfeel and flavour in the final beverage. Preferably, in order to avoid sediment or other problems, the mass contains less than 30wt%, more preferably less than 20wt%, more preferably less than 10wt% of insoluble materials. In some embodiments, such as hot chocolate beverages, it may be preferred that there is substantially no insoluble material, so as to provide a smooth mouthfeel.

While this disclosure is provided primarily in relation to hot chocolate beverages, it will be appreciated that the method and advantages apply equally to the other suitable beverage ingredients discussed herein, such as coffee beverages. The present inventors have found that by using the method described herein they can provide a soluble beverage mass that can be dissolved to create a hot or cold beverage. In particular, the method allows the provision of hot or cold beverages such as chocolate drinks, instant coffee and coffee mixes, tea, fruit mixes or speciality drinks using a combination of ingredients including but not limited to foaming and/or non-foaming creamers, instant coffee, sugar or sweeteners, milk powder, non-dairy creamer and cocoa powder possibly containing flavouring. Moreover, the feed material can include nutritional components such as minerals and vitamins.

Furthermore, the resulting beverage can have foam and different inclusions bringing the surprise element with inclusion rising on the top, sinking to the bottom or being hidden in the foam. It also provides multisensorial experiences with the use of foam, liquid and crunchy, soft etc. inclusions. The beverage is typically prepared by placing the soluble beverage mass into a cup and adding 150-200 ml_ of hot/cold liquid (such as water or milk), optionally followed by either immediate or delayed (around 5 seconds) stirring for 25-45 seconds.

The product produced according to the method described herein typically looks like a plain beverage tablet. As a result, the presence of the inclusion, especially if it has a delayed release after dissolution, provides an element of surprise, joy and entertainment to the consumer which is not otherwise provided.

Inclusions typically rise to the surface/sink to the bottom within 20 seconds in hot water/milk. The soluble beverage mass typically completely dissolves within 30-45 seconds measured from the moment hot water/milk gets into contact with the mass. Complete dissolution is determined through visual inspection. The same preparation method of other products on the market (e.g. Jiva cubes tm ) was found to lead to dissolution times of more than 60 seconds.

Advantageously, the soluble beverage mass is compact, acquiring less packaging versus alternative beverage offerings in sachets (loose powders, adjuncts etc.). The compact format of the soluble beverage mass has further advantages for travelling and sharing. It is small (typically around 15 ml_, appealing and portable. It easily fits into small handbags, providing convenience. One soluble beverage mass of 15 mL is enough to prepare one drink of cup size. Alternatively the method can be used to produce multiple soluble beverage masses delivering the same drink concentration in the same final volume. Traditionally powdered ingredients when compressed to such a small volume are negatively affected in terms of dissolution. However this novel soluble beverage mass easily breaks open when inclusions are present while preparing the drink. This is because the inclusions interrupt the homogeneity of the soluble beverage mass thus creating more channels for water penetration

That is, the inventors have found that, by using a preheated mould and by ensuring that the inclusions are retained within a central portion of the mass, they can provide a tablet form mass which dissolves well but has a suitable resilience for transport and handling. This balance has not been previously attained in the prior art.

The present inventors have analysed the tablets known in the prior art and have found that tablets formed by conventional heating techniques have a very different internal structure compared to the masses of the present disclosure. Specifically, highly compressed tablets have a homogeneous but brittle and unfused internal structure. They typically have a very slow dissolution time. Tablets which rely on added binders tend to have unnecessary mass and the flavour of the final beverage may be affected by any binder residue. The present inventors have found that the methods of the present disclosure provide a sufficiently robust mass having a good cohesiveness. This ensures that the mass is sufficiently robust for manufacture (transport on conveyor belts), transport and handling, while providing a good dissolution rate.

The method of the present disclosure comprises a number of steps. In a first step, one or more soluble beverage ingredients are provided in powder form. By powder form it is meant to include finely divided dry particulate matter and granules such as spray dried particles, freeze-dried particles and agglomerates thereof. Typically the particulate material will have a particle size of less than 3mm, more preferably from 2.5mm to 10 microns, more preferably from 1 mm to 300 microns and more preferably about 500 to about 700 microns. By particle size it is meant a D50 of the particles and methods for determining these are well known in the art using dry laser diffraction techniques. Such particles are well known in the art. Examples of suitable materials are discussed in more detail below. Surprisingly, due to the method of manufacture disclosed herein, the dissolution properties of the masses reflect those of the starting material because the structure of the starting powder is not significantly changed. The use of a powder form of the ingredients aids in the ready and reproducible filling of the mould cavity.

The apparatus used for performing the present method is also very important. The apparatus comprises a mould having a mould-cavity. This mould is preheated so that a contact surface of the mould cavity, which in use contacts the soluble beverage ingredients, is at an elevated temperature. The mould cavity is loaded with the one or more of the soluble beverage ingredients so that they contact the preheated contact surface at an elevated temperature. The present inventors have found that this serves to provide a more resilient soluble beverage mass than would be achieved if the mould was not preheated. That is, the use of a preheated mould makes the mass more resistant to breakage when transported and handled following

manufacture.

The mould may be provided with a lining to aid in the removal of the soluble beverage masses after formation. The various components of the mould, the lid and any mould lining are preferably each formed of a dielectric material. This is advantageous because the dielectric material can be readily pre-heated and/or heated with RF radiation. This means that the surfaces of the mould- cavity can be heated with a single RF heat source, simplifying the production method. Suitable dielectric materials include PVDF or a polymer, such as silicone, containing particles of carbon black.

The soluble beverage ingredients are loaded into the preheated mould in several steps as discussed below. A lid or closure is then typically applied and this can be used to apply the compression to the ingredients. Preferably the lid or closure is preheated to the same temperature as the mould-cavity. The compression step serves to compress the one or more soluble beverage ingredients in the mould-cavity to form a soluble beverage mass. The compression step helps to fuse the ingredients together.

To be loaded into the preheated mould, the soluble beverage ingredients are divided into a first portion, which is loaded first. One or more discrete inclusions are then loaded onto the first portion. Then a second portion of the one or more of the soluble beverage ingredients is loaded. This ensures that the discrete inclusions can, if desired, be entirely encapsulated within the soluble beverage materials.

Inclusions can be of soluble and insoluble nature. Soluble meaning that they dissolve/melt after a while such as marshmallows. Insoluble meaning that they retain their shape such as jelly beans. Soluble and insoluble inclusions can be but are not limited to marshmallows, milk/dark/white chocolate pieces, biscuits or biscuit pieces, cereals, jelly beans, popping candy, encapsulated syrups, encapsulated flavourings, dried fruits and spices, the inclusions may also be enrobed in milk/dark/white chocolate or other edible coatings. Sizes of inclusions are preferably 0.05-2 cm and can have any shape and density to achieve either sinking or rising/floating. The inclusions are preferably larger than the particles of the soluble beverage ingredients, preferably at least twice the size (D50), more preferably at least 10 times the size. Typically, notwithstanding the relative sizes of the particles, the soluble beverage powders form a discrete continuum of the beverage mass when compressed, whereas the inclusions may remain discrete in the mass to form discrete bodies in the final beverage. For example, where marshmallows are used as an inclusion within a chocolate beverage powder, the chocolate beverage powder will form a substantially uniform portion of the beverage mass, whereas the marshmallows will remain separate bodies: even if held together within the beverage mass they will typically not merge together. Preferably the discrete inclusions are selected from marshmallows, chocolate pieces, popping candy (containing pressurised gas), rice puffs, chocolate beans, jelly babies, sugar balls, dried fruit, choco pops, corn flakes, sugar covered chocolate beans, gum pieces, encapsulated syrups and flavourings (to provide a delayed change in the beverage flavour), honeycomb, nuts, jelly beans and honey loops. Of the inclusions, mini marshmallows, popping candy, colourful coated puffed rice flakes, cinnamon flavoured dried apple pieces, bigger marshmallows with popping candy. Rice Crispies, Choco Pops, and Honey Loops are preferred because they float on a beverage and are a surprising addition from the mass. Of the inclusions, chocolate beans, coloured sugar balls, decoration icing figures and Jellies Babies are preferred because they float and provide a surprise at the end of the drink. Of the inclusions, popping candy is preferred because it dissolves audibly. It is particularly advantageous for the popping candy to be co-filled with a portion of the one or more soluble beverage ingredients because of its small size.

The one or more discrete inclusions preferably have a mean longest diameter of from 0.05cm to 2cm, preferably from 0.1 to 1 cm in size. The most preferred size will depend on the type of inclusion to be used. For a marshmallow, for example, a larger size is preferred, although it must be noted that above a certain size the integrity of the mass may be compromised. For popping candy, for example, a finer size is preferred to ensure a quick dissolution and a loud audible noise when contacted with water.

Preferably the inclusions form from 10 to 90wt% of the total beverage mass, preferably from 40 to 60wt% and most preferably about 50wt%.

Preferably the inclusions are provided substantially in the centre of the beverage mass. In this way they may not be released immediately, adding to the surprise for the consumer when they subsequently appear in the beverage.

Preferably the ratio of the first and second portions of the one or more soluble beverage ingredients is from 2:1 to 1 :2.

In one embodiment, the discrete inclusions are loaded into the mould cavity in a pre-prepared mixture with a third portion of the one or more soluble beverage ingredients. This is

advantageous because it ensures that there are no gaps in the beverage material and leads to the formation of a more robust final beverage mass. This also may help to keep the inclusions as discrete bodies within the beverage mass and prevent them merging together. Preferably the ratio of the first and second portions to the third portion of the one or more soluble beverage ingredients is from 2:1 to 10:1 .

Preferably a stress between 0.5MPa to 1 MPa is applied to the contents of the mould-cavity, preferably about 0.65MPa. Preferably the one or more soluble beverage ingredients are compressed within the mould-cavity for at least 30 seconds, preferably from 45 to 120 seconds. Preferably the step of compressing reduces the volume of the mould contents by from 10 to 50% of the initial volume.

Preferably the one or more soluble beverage ingredients are retained within the mould-cavity for at least 30 seconds, preferably from 45 to 150 seconds. Without wishing to be bound by theory, it is considered that this duration allows heat from the pre-heated mould to permeate through the mass and cause a more consistent internal structure. It is considered that a shorter time, particularly for larger masses, would not allow the provision of a suitably robust final product while substantially retaining the porous structure and dissolution properties of the original powder. Equally, if the duration is too long, such as more than 120 second, the powder may fully agglomerate into a solid or glassy body.

Preferably the inclusions are entirely encapsulated within the beverage mass. More preferably, the inclusions are provided within only the inner 75% of a radius from the beverage mass centre, more preferably an inner 50% of the radius. This ensures a clean outer appearance and a surprising presence of the inclusion in the final beverage.

The present inventors have sought to provide a premium beverage product, particularly a coffee product, with all of the convenience of soluble products, while avoiding the various

disadvantages of and prejudices against such products. Specifically, the inventors have sought to provide a beverage ingredient which provides a consistent final beverage, without requiring a dispensing machine and which is easily stored, transported and used.

It has already been recognised that tablets address several of these problems, but it has never been possible to produce a tablet which is sufficiently acceptable to consumers to attract consumers who typically prefer fresh from roast and ground coffee beverages.

It is considered that there is a certain amount of ceremony and associated preparation involved in the preparation of a final beverage from roast and ground coffee. The consumer of such beverages associates this effort in the preparation with the beneficial properties of the final beverage. In contrast, soluble coffee beverages are prepared in an instant with the addition of hot water. The present inventors have now recognised that the instantaneous nature of soluble coffees may contribute to the prejudice against such products. Accordingly, while of course seeking to avoid residues and deposits within the final beverage, the inventors have realised that some control of the dissolution time is desirable. Accordingly, it is thought to be ideal if the beverage can take at least 10 seconds and no more than 100 seconds, preferably no more than 60 seconds to prepare following the addition of a hot aqueous medium to the ingredients. Preferably the preparation takes from 20 to 40 seconds for the full dissolution to occur with gentle stirring of the combined medium and ingredients. The present inventors have found that the method of the present disclosure provides a tougher mass having a substantially constant density. This ensures that the mass is sufficiently robust for manufacture (transport on conveyor belts), transport and handling, while providing a good dissolution rate and surprising further mouthfeel dimensions to the final beverage.

Preferably the soluble beverage mass has a weight of from 2 to 20g. Preferably the beverage mass is sized suitably to provide a beverage from a single mass. That is, preferably the mass is from 12 to 18g, more preferably from 15 to 17g. These are typical values for the required solids necessary to provide full flavoured beverages of these types and to encapsulate the inclusions.

Preferably the mould and/or closure is preheated to a surface temperature greater than the Tg of the one or more soluble beverage ingredients. This allows the softening of the beverage ingredients so that a cohesive mass can be prepared. Preferably the mould and/or closure is heated to a temperature of from 80 to 120°C, more preferably from 100 to 120°C if the powder is not prewarmed and from 80 to 1 15°C if the powder is prewarmed. This range of temperatures has been found to be suitable for most beverage ingredients, especially soluble coffee, where is allows the provision of a cohesive mass without leading to a spoiling of the ingredients or any off- tastes. It is considered that the use of too much heating can cause scorching or off-flavours due to maillards reactions which can occur.

Preferably the one or more soluble beverage ingredients in powder form are prewarmed before loading into the mould-cavity. That is, preferably the powdered soluble beverage ingredients are preferably prewarmed to a temperature within 10 ° C, preferably within 5 ° C of the glass transition temperature (Tg) of the one or more soluble beverage ingredients. Preferably the ingredients are heated to a temperature just below the Tg, although temperatures in excess of the Tg are also suitable. Temperatures above the Tg can lead to difficulties when filling the moulds.

The Tg is the reversible transition in amorphous materials (or in amorphous regions within semicrystalline materials) from a hard and relatively brittle state into a molten or rubber-like state. This is distinct from the melting point of the material and serves to render the material tacky. Tg's are highly dependent on moisture content and are well known in the art. By heating the powders close to the Tg they can be made to bind together. It should be noted that certain materials do not have a Tg, such as sugar which is crystalline. Preferably the soluble beverage ingredients described herein are heated to reach a temperature relative to at least the Tg of the major ingredient in a mixture, or the ingredients may be selected to have similar Tg values before producing the mass. By major ingredient it is meant the ingredient which is present in the greatest amount by weight in a mixture. As a general rule of thumb, Tg values tend to be approximately 2/3 of the melting point of a material.

The inventors have found that, surprisingly, the use of a prewarmed powder significantly reduces the pressure required to compact the ingredients and form the beverage mass. Moreover, a more homogeneous and robust structure can be formed, without compromising the porosity of the starting material or the speed of dissolution. The inclusions may be prewarmed to help the powder ingredients form a tablet, or chilled to prevent the inclusions from clumping together.

Preferably the mass is cooled to room temperature or below and then removed from the mould. This helps to prevent damage of the product after the manufacture process. In general terms it has been found that the mass should at least be cooled below its glass transition temperature (Tg) before removal from the mould.

Preferably, after loading the mould-cavity with the ingredients, the method further comprises a step of sealing the mould cavity with a lid having a further contact surface. The lid preferably has the dual purpose of providing even heating around the mould contents while being able to provide the necessary in-mould compression. Preferably the further contact surface of the lid is formed of a dielectric material and/or wherein the lid comprises a dielectric material and is provided with a lining or coating to form the contact surface. This allows the lid to be pre-warmed with RF heating, although other heating techniques are also suitable.

While in the closed mould the ingredients may be heated to form the beverage mass. This may be achieved with RF heating, microwave heating or with resistive heating. In a preferred embodiment, however, there is no additional heating step, since this reduces the complexity of the process and there is a reduced requirement to heat through to the centre of the mass in view of the inclusions provided therein which do not need to be fused together. Indeed, if the heating applied is too great, then the inclusions may be damaged or even destroyed.

Preferably the heating is carried out before and/or after the soluble beverage ingredients have been compressed within the mould-cavity to form a soluble beverage mass.

RF heating techniques are well known. RF, also known as dielectric heating, is a process in which a high-frequency alternating electric field, or radio wave or microwave heats a dielectric material. At higher frequencies, this heating is caused by molecular dipole rotation within the dielectric. The RF heating described herein encompasses microwave heating (up to around

2.5GHz) and can typically be carried out at a frequency in the range of from 10 to 10OMhz, more preferably from 10 to 45Mhz and most preferably from 25 to 30MHz. Most preferred are frequencies of 13.56, 27.12 and 40.68 MHz. Preferably the one or more soluble beverage ingredients comprises soluble coffee, creamer, milk solids, sugar, flavourings, colourings, cocoa or chocolate, or a mixture of two or more thereof.

Preferably the one or more soluble beverage ingredients are loaded into the mould cavity together with particles of finely ground coffee beans, preferably having a D90 of less than 300 microns. Combined soluble coffees and finely ground roast and ground coffee are well known in the beverage market, such as Millicano™. Alternatively, the soluble coffee may simply be premixed with a finely ground roast and ground coffee powder. The addition of roast and ground coffee in these ways has been found to cause both a surprising increase in the solubility of the beverage mass and an increase in the strength of the mass. Without wishing to be bound by theory, the insoluble particles appear to provide a structure to the masses and also a point of weakness for the infiltration of the aqueous medium into the mass. Preferably the soluble coffee contains particles of finely ground coffee beans, the ground beans preferably having a D90 of less than 300 microns and a D50 of from 5 to 60 microns.

Preferably the one or more soluble beverage ingredients comprise two or more ingredients and wherein the soluble beverage ingredients form separate layers or separate portions within the mass. This provides a pleasing appearance to the final product and can also allow for temporal profiling of the dissolution of the different ingredients (i.e. an outer milk foam may be formed first, followed by a central coffee layer to ensure that the foam on the beverage is white). Preferably the ingredients are not mixed together but instead form visibly discernible layers to provide an impression of the beverage ingredients to the consumer.

In another embodiment, the ingredients may first be agglomerated together before the forming of the soluble beverage mass. Alternatively the ingredients may be combined and then spray or freeze-dried.

Preferably the soluble beverage mass comprises two or more of soluble coffee, creamer, chocolate and wherein each is included in at least one separate discrete layer or portion of the mass. The beverage ingredients are provided in powder form and preferably comprises particles having a D99 of 800 microns or less and/or a D50 of 300 microns or less. Techniques for measuring these parameters are well known in the art. It is preferred to use a Malvern Dry laser diffraction technique. In one embodiment the one or more soluble beverage ingredients comprise soluble coffee and, in addition, from 0.01 to 0.1 g of coffee oil is added to the mould with the one or more soluble beverage ingredients. Coffee oils, such as Coloma oil, are typically added to instant coffees in order to provide a strong coffee aroma. By including the oil in the mould with the ingredients the aroma may be preserved with the masses and released on preparation of a beverage.

Preferably the one or more soluble beverage ingredients comprise a foaming soluble beverage ingredient containing trapped pressurised gas. Suitable methods for producing such an ingredient are disclosed in EP 1627568, the contents of which are incorporated herein by reference. Preferred embodiments include foaming soluble coffee and, foaming soluble creamers and foaming soluble milk powders. This allows for the formation of a crema on the surface of the final beverage. Alternatively, if sufficient gas can be trapped then the beverage itself may be partially foamed.

Preferably the soluble beverage ingredients in the mould-cavity are not subjected to RF heating. This has been found to risk damaging the inclusions. Preferably the one or more soluble beverage ingredients do not comprise a binder. That is, there is no need to include a glue or other ingredient that is not required in the final beverage in order to produce the soluble masses. This is because the method of the present invention is suitable for the formation of masses without a binder.

Preferably the one or more soluble beverage ingredients have a moisture content of from 0.1 to 6wt%, preferably from 2 to 5wt%. This level of moisture content allows the masses produced therefrom to fuse easily in the mould-cavity and is also sufficiently low to allow a long shelf life of the final product. The product should be shelf stable at 20 ° C for a period of at least 6 months, preferably at least 12 months.

The soluble beverage mass is preferably made and then sealed into substantially air- and moisture-impermeable packaging for sale. In this way it is possible to prevent any degradation of the product before use.

Preferably a closure for the mould cavity provides the soluble beverage mass with a substantially flat surface, or a surface having a peripheral portion on which the mass can stably rest and a central indented portion defining a cavity within the mass. It is desirable that the soluble beverage mass is able to stably rest upon a surface. This allows, for example, the transport of the soluble beverage mass on a conveyor belt without the risk of it rolling away. Thus, preferably the soluble beverage mass is provided with a substantially flat surface formed by the lid.

Alternatively, the soluble beverage mass is provided with a surface formed by the lid having a peripheral portion on which the mass can stably rest and a central indented portion defining a cavity within the mass. For example, the surface formed by the lid may provide the mass with a rim and a concave cavity, whereby the mass may rest on the rim when placed on a flat surface. It will be appreciated, of course, that a resting surface may be provided by the mould-cavity and not by the lid per se. However, it has been found that the use of shaping features within the mould-cavity may cause difficulties when retrieving the mass from the mould. Preferably the soluble beverage mass is transported after production on said surface formed by the lid. In one embodiment the lid includes a stamp or cavity, whereby a marking can be formed on the mass during the compression. This is useful for providing branding or an identification of flavour. According to a second aspect, there is provided a soluble beverage mass obtainable by the method disclosed herein.

According to a third aspect there is provided a soluble beverage mass comprising one or more soluble beverage ingredients and having a weight of from 12 to 20g, the soluble beverage mass having a density of from 0.5g/cm 3 to 1 .7g/cm 3 , and a surface hardness breaking force of at least 10N, and containing one or more discrete inclusions having a mean longest diameter of from 0.05cm to 2cm.

Preferably the inclusions are less soluble than the soluble beverage ingredients, such that the inclusions do not dissolve within at least 5 minutes of the dissolution of the beverage mass. Preferably the mass dissolves completely within 20-40 seconds of immersion in 200ml of 80- 95 ° C water with gentle stirring.

The soluble beverage mass may be provided with any suitable shape and surface texture.

Preferably the surface is substantially smooth. In various examples, the soluble beverage mass is shaped as a hemisphere, an elongate hemisphere and/or a prolate hemisphere. These rounded shapes are reminiscent of the shapes of fine chocolates and this imports an impression of quality in the finished product. According to a fourth aspect there is provided a method of preparing a beverage, the method comprising contacting the soluble beverage mass described herein with an aqueous medium. While the aqueous medium will generally be water, it may alternatively comprise or consist of milk. The aqueous medium may be at any suitable beverage temperature but preferably has a temperature of from 75 to 95 ° C.

According to a fifth aspect there is provided a beverage preparation system for preparing a coffee beverage, the system comprising means for providing an aqueous beverage medium to the soluble beverage mass disclosed herein to dispense a beverage from the system. The beverage masses described herein are particularly advantageous for use in circumstances where there is a lack of suitable beverage preparation space or equipment. For example, such masses may be ideally suited for preparation of multifaceted beverages in airplanes or trains, for example. Especially in such circumstances, the aspect of surprise which may arise from the discovery of inclusions floating to the top of a beverage or found at the end of the beverage provides a unique and pleasing beverage product.

According to a further aspect there is provided a method for producing a soluble beverage mass, the method comprising:

i. providing one or more soluble beverage ingredients in powder form,

ii. providing a pre-heated mould having a mould-cavity,

iii. providing one or more discrete inclusions,

iv. loading the mould-cavity with the one or more of the soluble beverage ingredients and the one or more discrete inclusions,

v. compressing the contents of the mould-cavity to form a soluble beverage mass. All of the features described in relation of the other aspects above apply equally to this further aspect. That is, for example, the mould, ingredients and inclusions of those aspects can be used in this further aspect. Preferably in the step of loading the mould-cavity, the one or more of the soluble beverage ingredients are loaded into the mould cavity before or after the one or more discrete inclusions. Preferably the one or more soluble beverage ingredients are loaded into the mould cavity separately from the one or more discrete inclusions. The invention will now be described in relation to the following non-limiting figures, in which:

Figure 1 is a schematic of the equipment used in the process described herein.

Figure 2 shows the mould loading steps of the method.

Figure 3 is a cross-sectional diagram of a beverage mass produced according to the method disclosed herein.

Figure 4 is drawing of a beverage produced from a beverage mass as described herein.

Figure 5 is a flowchart of an embodiment of the method described herein. In this flow chart, the method steps are as follows:

In step A a chocolate powder is provided.

In step B a first amount of the chocolate powder is loaded into a pre-heated mould having a mould-cavity.

In step C, an amount of finely divided marshmallows are introduced onto the chocolate powder held within the mould.

In step D a second amount of the chocolate powder is loaded into the pre-heated mould.

In step E, the ingredients are optionally compressed to form a compressed beverage mass.

In step F the mass formed is demoulded and in step G the masses are packaged for distribution and sale.

As shown in Figure 1 , a soluble beverage mass 1 may be produced as follows. A mould 5 is provided with a PVDF lining 10 which lines the outside of a mould cavity 15. The lining 10 is pre-heated with an RF source (not shown) to a temperature of about 100 ° C. Alternatively, the pre-heating can be achieved with a conventional heat source. Beverage ingredients 20 are filled in several steps into the mould cavity 15 and compacted with a plunger 25. The plunger 25 is formed from PVDF, preheated and used to form the lid of the enclosed mould 5.

The mass 1 is held in the compacted for 60 seconds. The mass 1 can then be easily turned out of the flexible lining 10. Figure 2 shows the individual steps for filling the beverage ingredients 20 into a lining 10 of the mould cavity 15.

The beverage ingredients 20 were provided in the form of a first portion 21 , inclusions 22, and a second portion 23. The first portion was loaded into the lining 10 and the inclusions 22 loaded thereon. The inclusions 22 were kept in a central portion of the mass to ensure that they would be entirely encapsulated. The inclusions were then covered with the second portion 23.

In this example, the beverage ingredients 20 were a pre-formulated hot chocolate powder with marshmallow and popping candy inclusions. These were loaded into the lining on a bed of 25wt% of the powder and then the remaining 75% was added to form the sides and top of the final mass. The ingredients 20 were compressed for 60 seconds to form the mass.

As shown in Figure 3, the mass 1 may be provided with a base 30 which is either flat or indented so as to provide a stable base formed by the peripheral rim 35.

Figure 4 shows a mug 1 1 of a beverage 12 formed from a beverage mass 1 and having marshmallows 13 therein.

The invention will now be described in relation to the following non-limiting examples.

Examples

All soluble beverage ingredients are turned into tablets using the following process, except where indicated below.

• Preheat PVDF mould with dielectric heating up to 1 10 °C.

• Fill the mould with half of feed material.

• Add the inclusions directly into the mould or premix them with a small quantity of the feed material.

· Cover the inclusions with the rest of the feed material.

• Compress the powder under 460 N for 60 seconds using a hydraulic press. • Discharge the soluble beverage mass.

Method of evaluation of soluble beverage mass To determine the dissolution time, the soluble beverage mass is placed into a cup. 200 ml of water with a temperature of 85 °C is added. The soluble beverage mass is stirred manually until dissolved. The time is measured in seconds from the moment when the water is getting into contact with the mass until completely dissolved. For hardness testing a Hounsfield equipment H25KS-0231 with a load range of 250 N is used. The soluble beverage mass is placed under a plate. The plate is lowered at a speed of 2 mm/min.

Example 1 :

6.5 g of Milka powder were filled into a PVDF mould of 1 10 °C. Small marshmallows were added on top of the powder. 6.5 g of Milka powder were added on top of the small marshmallows to cover them. The mixture was compressed for 60s under 460 N force. Afterwards, the soluble beverage mass was demoulded. The small marshmallows were not visible. The soluble beverage mass itself took around 30 seconds to dissolve with the small marshmallows floating to the top. The first marshmallow floated to the top after 8 seconds, the fifth and last marshmallow reached the beverage surface after 20 seconds. The marshmallows gradually melted after 30seconds adding a soft and sweet sensation in the drink. Example 2:

4 g of Milka powder was filled into a PVDF mould of 1 10 °C. A 5 g mixture of Milka powder and popping candy (50-50) was added. 3 big marshmallows were placed on top of the mixture and 4 g of Milka powder was added. The mixture was compressed for 60s under 460 N force.

Afterwards, the soluble beverage mass was discharge. The marshmallows were visible at the bottom of the soluble beverage mass. When dissolving the first popping sound and gas release from the popping candy occurred after 3 seconds and continues for approximately 40 seconds. Some foam is created. The first marshmallow floated to the top after 10 seconds, the third and last marshmallow rose to the beverage surface after 20 seconds. The marshmallows gradually melted.

Example 3:

6.5 g of Milka powder were filled into a PVDF mould of 1 10 °C. Chocolate beans were added on top of the powder. 6.5 g of Milka powder were added on top of the chocolate beans to cover them. The mixture was compressed for 60 s under 460 N force. Afterwards, the soluble beverage mass was discharged. The chocolate beans were not visible. When dissolving, the soluble beverage mass itself took around 30 seconds to dissolve with the chocolate beans sinking to the bottom after having been released. The chocolate beans create a nice surprise when drinking the beverage.

Example 4:

6.5 g of Milka powder were filled into a PVDF mould of 1 10 °C. Small marshmallows were added on top of the powder. 6.5 g of Milka powder were added on top of the small marshmallows to cover them. The mixture was compressed for 60 s under 212 N force. Afterwards, the soluble beverage mass was discharged. The soluble beverage mass was quite friable and fell into pieces when handled because the final density is lower than in Example 1 .

Example 5:

3 g of Milka powder were filled into a PVDF mould of 1 10 °C. A 5 g mixture of Milka powder and popping candy (50-50) was added. 3 big marshmallows were placed on top of the mixture and 5 g of Milka powder were added. The mixture was slightly compressed. Dielectric heating of 300 W was applied for 20 s. Next, the mixture was compressed for 60 s under 460 N force. The soluble beverage mass was discharged afterwards. When dissolving, the marshmallows were deformed due to melting during the process. No popping sound or gas release from the popping candy were observed since the volumetric heating had released the gas.

Example 6 (comparative)

6.5 g of Milka powder were filled into a PVDF mould without preheating (-25 °C). Small marshmallows were added on top of the powder. 6.5 g of Milka powder were added on top of the small marshmallows to cover them. The mixture was compressed for 100 s under 212 N force. Afterwards, the soluble beverage mass was discharged. The soluble coffee mass was very friable and powdery and lost most of its surface powder when slightly touched.

The inventors also contemplated the disclosure of EP1768502 and the method disclosed therein since it employs similar ingredients. However, the density of the final article is low (0.1 -0.6 g/mL), so it requires a coating to keep the powder particles together. The coating adds disadvantages for the preparation of the beverage as it delays the dissolution.

Furthermore, the concentration that the consumer expects in a 200 ml beverage is between 7 and 20% of solids. However the density of the powder described in EP1768502 is such that the confectionary can be used for a beverage preparation having a volume of 43-260 ml (cube edge 3.5 cm to 6.4 cm) compared to 15 ml that is described herein. The confectionary from

EP1768502 resembles a soluble beverage mass with cube dimensions of 3.5 cm to 6.4 cm. On closer inspection it becomes apparent that the current process solves the problem of producing a soluble beverage mass with a much simpler process comprising less steps. Besides having fewer steps, the novel process also offers a benefit of creating a foaming drink without the need of any additional ingredients. Usually sintering of foaming powder by oven method leads to a melting of the powder particles and a gas release during the processing. By only heating the soluble beverage mass through the surface area, the physical structure of the inside of the mass can be kept intact. The gas remains trapped until the powder is dissolved. It can also ensure, that flavours, nutritional components, oils and mixtures thereof which are either entrapped or located in the middle of the mass, remain intact.

Although preferred embodiments of the invention have been described herein in detail, it will be understood by those skilled in the art that variations may be made thereto without departing from the scope of the invention or of the appended claims.