Technical field

The present invention relates to a method and associated production system for controlling maturation of a beverage. Particularly, the invention is concerned with implementing process parameters that enable maturation, i.e. broadly achieving a change in flavour, or replicating the ageing effect of a liquid beverage product to be mimicked and/or accelerated, i.e. so that an overall product expectation or quality is replicated and/or time to market for the product is reduced. The product may be a non-alcoholic distillate.

Background to the invention

Various methods have been proposed for making an alcoholic beverage having the sensory characteristics of a traditionally aged, distilled spirit. For example, W02017/066740A1 (Brain Brew Ventures 3.0 LLC) outlines a method where a specified ratio of wood chips is introduced to a distilled alcoholic spirit, with pressure applied to create interaction between the wood chips and spirit. The intent of such methods is that the taste of the spirit, traditionally associated with storage in a wooden barrel for a number of years, is replicated by an accelerated process.

The prior art in this field is typically concerned with high alcohol content distilled spirits and multiple cycles of processing. Meanwhile, the production of distilled beverages that are substantially non-alcoholic in nature is a relatively recent development. As such, there exists a desire for replicating the taste, e.g. via a maturation-type process, of alcoholic drinks in a non-alcoholic format or to create new flavours and product opportunities.

The term "non-alcoholic beverage" is generally understood by a skilled person, with reference to applicable regulations, to be a beverage containing less than 0.5 % ABV of ethanol. Summary of the invention

The present invention seeks to present a repeatable process for production of a nonalcoholic beverage that is "matured" in the presence of wood to provide a desirable taste profile.

In a broad aspect implementing the invention a method is defined according to claim 1. An apparatus and system according to the invention is defined at claim 12. Other useful method steps and features are outlined in dependent claims.

In particular, there is provided a method of controlling maturation of a non-alcoholic beverage including the steps of: providing a non-alcoholic distillate to a vessel; providing an extraction medium to the vessel; subjecting the distillate in the vessel to heat and/or agitation; maintaining heat and/or agitation for a time period.

In one form agitation is provided by an ultrasonic means or other physical movement. Heat applied may be generally between 30 to 50°C or up to 70°C.

The primary purpose of the invention is to 'age' or 'mature' the liquid, i.e. through the physical process that the beverage is subjected to, where wood flavour (from wood chips, being the "extraction medium") is extracted into it. The product is not necessarily a simulant of an alcoholic spirit but may have the same or similar kind of taste character, quality and complexity.

The beverage types of relevance to the invention include soft beverages/d rinks, nonalcoholic beverages/d rinks, non-alcoholic spirits, non-alcoholic 'adult' beverages/drinks.

A particular aspect of the invention involves outlining a complete process for the production of an aged non-alcoholic beverage from a raw material to a deliverable concentrate or ready to drink product. In a particular form, the first step in the process is extraction/maceration of a food source with water/steam. The starting material may be either (in a prepared or modified, heat treated, whole or ground form, alone or in combination): molasses, rye, barley or other grain, cereals (wheat, maize, corn, oats), agave, soy (e.g. Shochu), grape, stone fruit, rice, sorghum, cassava, sugar cane, sugar beet, or other sugar source. The material may be a mixture of any of the foregoing, i.e. any suitable food material/source.

Water or water-based extraction media (+fuse I, acid, salts, PG, flavour solvent) may be added at a known temperature. A mash filter may be used (or other solid/liquid separation), in which case wort is produced.

The mixture or wort (as applicable) is transferred to a still. Stirring/mixing/air rousing is performed and consideration given to dissolved oxygen control.

The distillation step itself involves heating and passing the evaporate over a condenser/cooler, to be collected in a downstream vessel. The key product from the distillation step is the non-carbohydrate portion of the mixture (alternatively termed as: the non -fermentable material, the volatile organic material, the flavour volatiles). During the distillation step, the vapour produced during heating includes flavour volatiles which, when the evaporate is then condensed, provides a distillate which has a higher concentration of the flavour volatiles relative to prior to the distillation step. Thus a non-alcoholic distillate is produced that is high in flavour. This is in contrast to the purpose of traditional distillation for an alcoholic mixture or wort, which is to separate the ethanolic fraction (being an unflavoured solvent) of a fermented liquid in order to produce an ethanol-based distillate, with flavour subsequently being generated during the maturation and finishing processes that occur after the distillation step.

At a next step preservatives may be added, e.g. citric acid, potassium sorbate, sodium benzoate / mixtures thereof. The distillate/preservative mix may be stirred/refrigerated (even potentially frozen), preferably at pH 4.5 or less. A maturation step is then performed on the mix, i.e. a process to extract desirable flavours from wood akin to traditional maturation or aging processes, thereby imparting matured or aged character. This process may be characterised as an accelerated and controlled extraction, rather than necessarily a mimic of traditional maturation.

In this step the distillate/preservative mix is treated in a maturation vessel where wood is present (e.g. in the form of chips or another suitable format). In a preferred form the vessel is subjected to ultra-sonic energy, e.g. sonication via an ultra-sound source such as a probe, jacket, and/or base.

In one form the vessel is agitated/stirred.

In one form heat and/or pressure may be applied to the vessel, optionally in the presence of air/oxygen. Such treatment will be implemented for a finite and known time period, e.g. less than one day.

In one form the matured distillate is filtered downstream of the maturation vessel.

Optionally, the distillate may be pasteurised, sterilised, refrigerated and/or frozen.

A further step of the production process involves transfer to a blending vessel for additives to be blended with the matured distillate. Additive options include, alone or in combination: sugar e.g. fructose or other sweetener, potassium chloride, trisodium citrate, phosphoric acid, malic acid or other fruit-derived acid, fusel oils, flavours, other carbohydrates or combinations thereof.

The product may be blended, filtered to provide a liquid which is '100% distillate.' The invention seeks to produce a non-alcoholic food (e.g. grain)-derived wood matured beverage with flavour notes of both wood and the food starting material (e.g. grain).

The concentrated form may be transported to end-markets and diluted to a ready to drink form, e.g. 100% distillate may be diluted by up to 40% water to create a >50% non-alcoholic matured distillate. It is noteworthy that, throughout the preferred process, flavours are only extracted, not removed or modified.

There are a number of potential variations to the total process as described above. For example:

• whole, milled grains, or a mixture of the two, could comprise the starting material;

• grains or feedstock may be pre-treated, e.g. acidification of wort-style mixture for flavour development;

• toasting or cooking of grain as part of process or as a defining flavour stage of process;

• extraction could be at ambient or increased temperature;

• fusel oils could be added at an earlier step, such as prior to distillation (e.g. addition to sour mash would drive potential esterification and flavour creation);

• the extraction medium pH may be adjusted (up or down) or augmented with salts or other solvents (e.g. polyethylene glycol, but preferably not ethanol);

• the filtration process, mash filter could be replaced by other separation process (e.g. centrifuge or plate, tun) or not filtered at all (grains in);

• pre-distil lation in still may involve oxygen control/blanket gas or air- rousing/agitation;

• alternative extraction of grain/starting materials may use steam, suspension of material in vapour to generate flavour before condensing/phase change (e.g. to avoid creation of wort as a by product);

• preservation steps/additives may be introduced at any time;

• the maturation stage may include cycling of temperature and/or pressure and/or introduction of air/oxygen

Brief description of the drawings

Figure 1 illustrates a first process stage associated with producing a non-alcoholic beverage distillate; Figure 2 illustrates a second process stage according to the invention where the distillate flavour is altered to simulate ageing; and

Figure 3 illustrates a third process stage associated with blending and producing a non-alcoholic beverage for distribution.

Detailed description of the invention

The following description presents exemplary embodiments and, together with the drawings, serves to explain principles of the invention. However, the scope of the invention is not intended to be limited to the precise details of the embodiments or exact adherence with all steps, since variations will be apparent to a skilled person and are deemed also to be covered by the description. Terms for components used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided but such terms are not intended to be exhaustive.

Descriptive terms should also be given the broadest possible interpretation; e.g. the term "comprising" as used in this specification means "consisting at least in part of" such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Directional terms such as "vertical", "horizontal", "up", "down", "upper" and "lower" may be used for convenience of explanation usually with reference to the illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and/or direction.

The description herein refers to embodiments with particular combinations of steps or features, however, it is envisaged that further combinations and cross-combinations of compatible steps or features between embodiments will be possible. Indeed, isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination.

Figure 1 outlines an example of a distillation process for producing a non-alcoholic beverage product. According to the example, a raw material is selected from a store 10 with the options of molasses liquid syrup, pre-milled rye grits and pre-milled (e.g. malted) barley grits. The selected raw stock is passed through a mash filter 11, with heated water 12 and transferred to an intermediate collection tank 13 which defines a batch size for the downstream process. The starting material 10 may be (in a prepared or modified, heat treated, whole or ground form, alone or in combination): molasses, rye, barley or other grain, cereals (wheat, maize, corn, oats), agave, soy (e.g. Shochu), grape, stone fruit, rice, sorghum, cassava, sugar cane, sugar beet, or other sugar source. The material may be a mixture of any of the foregoing, i.e. any suitable food material/source.

In the illustrated form the warm batch liquid is transferred to a still 14, subjecting it to indirect heating 15 and optional agitation 16. A water inlet 17 provides water to the still 14 and may also provide a source of fusel oil to enhance the carry-over of volatile flavours into the distillate. By way of example, the amount of water may be 15-20m ³ per day or as required for distillation.

A vent 18 releases excess pressure (and/or provides an anti-vacuum function) while vapour is directed to a condenser 19 having a cold water inlet 20 and a warm water outlet 21. Distillate, condensed back to liquid in condenser 19 is collected in one of the storage tanks 22, 23, 24 (e.g. as allocated to the type of distillate). In alternative forms, a single tank may be used and cleaned after each batch as necessary or the distillate may be transferred directly to a maturation vessel described hereinbelow with reference to Figure 2.

In a known way, distillate may be separated into heads, hearts and tails to ensure that the amount of fusel oil remaining in the liquid for consumption is controlled.

At tanks 22, 23, 24 (preferably under refrigeration to + 5°C) a preservative 25 may be added, such as citric acid, potassium sorbate or sodium benzoate. The pH is measured; e.g. approximately 4.5 or less at this stage of the process. Sample tests can be performed such as for carbohydrate in the distillate.

When the raw material of the batch is exhausted a substantial volume (material remnants) is discharged to storage R. The remnant volume from a batch may be approximately 80% and is useful as animal feed or the like since it is still high in nutrients.

Being a low/no-alcoholic process, the primary purpose of the process exemplified by Figure 1 is not to extract sugar for conversion to alcohol, but to extract base flavours from the raw material into the distillate. It is an aqueous system with one solvent (water) containing soluble volatiles. There is no fermentation stage.

Furthermore, no yeast is required in a non-alcoholic distillate process. In general, a higher heat can be applied because there is no danger of destroying the yeast, however, high heat may affect the liquid in other ways so there will still be an upper operating threshold. A preferred upper operating temperature is 70°C.

By way of observation the yield is approximately 18% for rye and barley variants compared to 40% for the molasses variant.

In a preferred form all (100%) of the collected distillate is utilised in the maturation process of Figure 2. However, some of the distillate may be retained for later blending.

Referring to Figure 2, a distillate selected from one of the tanks 22, 23, 24 (storing barley, e.g. malted barley, rye and molasses distillate variants respectively as seen in Figure 1) is pumped to a maturation vessel 26 (e.g. high polish stainless steel) which may include one or more of the following features: a vent T1 to outlet excess pressure, an agitator 28, at least one basket 29 to receive/hold wood chips, a sonication means (i.e. ultrasound input 30) and a vessel jacket/sleeve 31 that may comprise a heating function and/or the sonication means. The addition of woodchips as a raw material input is generally denoted 32, while the addition of heat is denoted by reference numeral 33; which may be a heating element applied to the base of vessel 26 or the sleeve. In one form the sonication means 30 may comprise a probe to provide additional agitation of the beverage. The illustrated example features a sleeve 31 with a surface vibrating at ultrasonic frequencies. Sonication, in the present context, refers to the process of applying sound energy to agitate particles or discontinuous fibers in a liquid. Ultrasonic frequencies (>20 kHz) are usually used, so the process is also known as ultrasonication. As mentioned, sonication can be conducted using either an ultrasonic bath (plate in contact with a volume of liquid) or an ultrasonic probe (sonicator).

Agitation/sonication is utilised to improve transfer of properties from the woodchips 32 (e.g. 50 to lOOg/L blend of high spice and used oak barrel wood which may be commercially available) into the distillate, e.g. put energy in to extract flavour for the purposes of mimicking an alcoholic beverage, however, unique and new taste profiles may be developed without reference to traditional alcoholic spirits. In principle, alternative carriers other than wood may be provided to the maturation vessel for the purpose of affecting the taste profile of the distillate. By way of example, sonication may be performed for a minimum duration of 30 minutes. Temperature may rise by ~ 8°C following a 30 minute sonication period.

The general temperature of the maturation vessel may be maintained at predetermined temperature and/or pressure. Pressurisation may be achieved by introduction of air or a higher-concentration of oxygen gas. In one form of the method, operating parameters may be optimised to achieve exhaustion (and hence most efficient use) of the woodchips, i.e. by altering parameters such as agitation, heat and/or pressure in order to reach flavour profile desired in the target liquids.

After a specified maturation period of the distillate in the presence of a medium (e.g. a natural fibre such as wood from which taste characteristics can be extracted) the distillate is optionally pumped through a filter 34 for downstream storage, e.g. into separate storage vessels 35, 36 and 37 designated for each variant. In alternative forms a single storage tank may be utilised (cleaned after each batch) or the matured liquid may be transferred directly to a blending stage outlined by Figure 3. Pasteurisation or other stabilisation measures may be required at the maturation stage, i.e. during downstream storage or incorporated with the maturation vessel. Pasteurisation temperatures may be sufficient to achieve maturation (flavour extraction from the wood) without or in addition to agitation measures. Temperatures should be limited, e.g. to 75°C, so that the product flavour is not degraded.

Remnants from the maturation process are removed for storage/disposal to tank 38 after/during cleaning of maturation vessel 26 at the conclusion of maturation.

Referring to Figure 3 a blending stage is outlined, downstream of the maturation stage of Figure 2. In this third stage a selected matured distillate, e.g. matured barley, rye or molasses, is pumped to a blending vessel 39 that includes a vent 40 and water inlet 41. Particularly, blending vessel 39 also includes an inlet 42 (or multiple inlets) in communication with a plurality of storage containers 43 respectively corresponding to an additive and/or flavour required for further refinement of the product. The additives may include fructose or other sweetener, potassium chloride, tri-sodium citrate, phosphoric acid, malic acid, fusel oils and varieties of flavour.

After blending the resultant product is transferred, via filter 44, to further storage tanks 45, 46, 47 allocated to the beverage product type and/or deliver options. Each vessel may be vented and/or refrigerated as needed.

The product may be transported in a bulk concentrated state for mixing with water at a filling/packing location. By way of example the final product may comprise 60% distillate from the blending stage with 40% water at a final fil ling/bottling/packagi ng state.

By way of general observation, it was unexpected that a distillate produced according to the invention would provide so much flavour.

Furthermore, the maturation process can be optimised based on dosage of woodchips, temperature, pressure, time, size of woodchip. By way of summary, in one form the invention can be described as a system and method of producing a taste enhanced non-alcoholic beverage (i.e. ready-to-drink or concentrate) including the steps of: providing a non-alcoholic distillate to a vessel; providing a solid medium for taste extraction to the vessel; heating the vessel and/or subjecting the distillate in the vessel to agitation; maintaining heat and/or agitation for a time period. In a preferred form the agitation step includes sonication.

In one aspect the invention is embodied by a system for producing an enhanced nonalcoholic beverage, the system comprising: a raw material storage container; a still in communication with and configured for receiving raw material from the storage container; a condenser in communication with the still configured for producing non-alcoholic distillate; an optional intermediate non-alcoholic distillate storage container in communication with the condenser; a maturation vessel configured for receiving non-alcoholic distillate and producing enhanced distillate, comprising: at least one porous container holding a solid extraction medium, a heating means, an agitator and/or sonication means; an optional intermediate enhanced distillate storage container in communication with the maturation vessel; a blending vessel configured for receiving enhanced distillate and producing a blended enhanced distillate, comprising: a plurality of inputs from respective vessels containing one or more of the following additives, alone or in combination: a sweetener, a preservative, a flavour, a fusel oil, a stabiliser, a buffer, a salt. The output blended enhanced distillate may be diluted (e.g. 60/40 with water) for filling into bottles for sale to consumers.

The invention is exemplified by a batch process with communication between production stages.