Field of the invention

The invention concerns a pod comprising a beverage ingredient for the preparation of beverages.

Background of the invention

It is known to prepare beverages by using a pod containing a beverage making ingredient in a dispensing machine. The pod has an inner volume in which a food or beverage ingredient is stored and in which a beverage or drink is produced when water is introduced inside.

In an eco-responsible approach, some of the existing pods are made of compostable or biodegradable materials.

In this document and as explained bellow, a difference is made between "industrially compostable" and "home compostable".

The characteristics that a material must possess so that it can be defined as "Industrially compostable" are established by several norms, such as the European Norm EN 13432 "Requirements for packaging recoverable through composting and biodegradation - Test scheme and evaluation criteria for the final acceptance of packaging" ISO18606, ASTM D6400. According to EN 13432, the characteristics that an industrially compostable material must present are listed below.

- Biodegradability, i.e., the metabolic conversion of the compostable material into carbon dioxide. The level of acceptance is 90% biodegradability to be achieved in less than 6 months and undertaken at a temperature of 58°C. - Disintegrability, i.e., the fragmentation and loss of visibility in the final compost (absence of visual contamination). Samples are composted together with organic waste for 3 months at a temperature between 40 and 70°C (driven by the biological process). At the end, the compost is sifted with a 2-mm sieve. The mass of residue of the test material with a size greater than 2 mm must be less than 10% of the initial mass.

- Absence of adverse effects on the composting process.

- Low levels of heavy metals and absence of adverse effects on the quality of the compost (e.g., reduction of the agronomic value and presence of ecotoxicological effects on plant growth).

- Other chemico-physical parameters that must not change after degradation of the material under study: pH; saline content; volatile solids; N; P; Mg; K.

No international standard defines for the moment the characteristics that a material must possess so that it can be defined as "home compostable”. However, some national norms, and in particular test protocol of certification bureaus, e.g. TLIV AUSTRIA BELGIUM company, define that the only differences, with "industrial compostability" are the following:

Biodegradability: the level of acceptance is 90% biodegradability to be achieved in less than 12 months and undertaken at a temperature of 28°C.

- Disintegrability: samples are composted for 6 months at a temperature of 28°C.

Up to now, the existing compostable pods do not present good mechanical, isolation and conservation properties Indeed, the pods of the state of art are fragile and easily subject to degradation due to oxidation, moisture, pressure variations, etc.

Therefore, the invention seeks to provide a pod for the preparation of beverages, which is compostable, preferably home compostable, and which is able to associate in a functional structure, proper mechanical, isolation and conservation properties.

Summary of the invention

The invention concerns a pod with an inner volume in which a beverage ingredient is stored and in which a beverage is produced when water is introduced inside, said pod comprising a first wall through which water is to be introduced and a second wall through which the beverage is to be dispensed, the pod being made of one or several compostable multilayer materials.

According to the invention, each of said one or several multilayer materials comprises at least one paper layer and at least one polymer barrier layer, said at least one paper layer and at least one polymer barrier layer being attached to one another by an adhesive layer, or by extrusion coating of the barrier layer to the paper layer, such as to bind them with a bond strength at least equal to 1.6N/15mm at 22°C, and 0.22 N /15mm at 100 °C. The use of an adhesive layer is preferred.

Thanks to the polymer barrier layer, the beverage ingredient is well conserved, and in particular well protected against oxidation and degradation by moisture. This composition of the pod provides a good shelf life for the consumer, as well as a fresh and quality product in the cup. Moreover, the thickness of the polymer barrier layer is defined such as to be satisfactorily pierceable by piercing elements of a beverage dispensing machine in which said pod is configured to be used. Furthermore, paper presents the advantage of being easily and rapidly recognizable as a compostable material by the consumer. This avoids mistakes that can be made by the consumer when throwing a pod.

Finally, bonding the paper layer and the polymer barrier layer strongly enough improves the mechanical strength of the pod and avoids cracking when the pod is subject to mechanical stress during storage or transport periods, for instance due to pressure variations or degassing of the beverage ingredient inside the pod.

In particular, the adhesive layer provides good bonding properties between both the paper layer and the polymer barrier layer.

In one embodiment, said adhesive layer is home compostable.

In one embodiment, the adhesive layer presents a homogenous thickness.

This feature improves the bonding between the paper layer and the polymer barrier layer.

In one embodiment, the adhesive layer is applied at an applied weight comprised between 2 and 15 g/m ² .

In one embodiment, the adhesive layer is made of a polyester- polyurethane elastomer, in particular Epotal ^® ECO 3702 available from BASF.

In one embodiment, the adhesive layer presents a thickness between 1 and 20 microns.

In one embodiment, said at least one polymer barrier layer is a plastic laminate.

Plastic laminate provides the desired mechanical properties, for instance with respect to the perforability and formability. The perforability is an important feature as the pod is intended to be pierced in the beverage dispensing machine. Moreover, the plastic laminate is stretchable, which makes it formable. In other words, it can be easily given a desired shape by stretching it without breaking or tearing.

It is advantageously possible to choose among the varieties of compostable plastic laminates.

In one embodiment, the plastic laminate comprises a Butenediol Vinyl Alcohol (BVOH) sheet sandwiched between two polymer sheets, said BVOH sheet being attached on both sides to said polymer sheets with tie sheets, said polymer sheets comprise the following polymers selected from the group consisting of polylactic acid (PLA), Polybutylene succinate (PBS) and aliphatic- aromatic polyesters like polybutylene adipate terephthalate (PBAT) or mixtures of these polymers.

The tie sheets gives high adhesion between BVOH sheet and polymer sheets.

In one embodiment, the polymer sheets are made of Ecovio ^® available commercially from BASF, in particular Ecovio ^® 40 FS23N1 EXP.

In one embodiment, the tie sheet is made of an adhesive resin including anhydride-modified polymers resin.

In one embodiment, said one or several multilayer materials further comprise a protective layer of a polymeric compostable material.

The protective layer prevents the plastic laminate from sticking to the beverage machine.

In one embodiment, the polymeric compostable material is regenerated cellulose. For example, the polymeric compostable material can be Cellophane.

In one embodiment, the one or several multilayer material further comprise an ink printing on one of its surfaces.

The ink printing can be for example artwork, information for the user and/or a code readable by the machine.

In one embodiment, at least one multilayer material comprises:

- a paper layer having a grammage comprised between 40 and

130 gsm;

- a first adhesive layer made of Epotal ^® ECO 3702 and which is applied at an applied weight comprised between 2 and 15 g/m ² ; and

- a polymer barrier layer made of a plastic laminate in which said polymer sheets are made of Ecovio ^® in particular Ecovio ^® 40 FS23N1 EXP and have a thickness comprised between 10 and 30 microns, each of said tie sheets being applied at an applied weight comprised between 2 and 8 g/m ² .

In one embodiment, said at least one multilayer material further comprises:

- a protective layer made of cellophane and having a thickness comprised between 10 and 50 microns, said protective layer comprising an ink printing on one of its surfaces; and

- a second adhesive layer attaching said paper layer to said adhesive layer, said second adhesive layer being made of Epotal ^® ECO 3702 and being applied at an applied weight comprised between 2 and 15 g/m ² .

In one embodiment, the pod comprises a body with a bottom wall through which water is to be introduced and a closing lid through which the beverage is to be dispensed, said closing lid being sealed on said body and defining therebetween said inner volume, the body being made of a first multilayer material and the closing lid being made of a second multilayer material different from said first multilayer material of the body.

In one embodiment, the body is made of said at least one multilayer material comprising said paper layer, said first adhesive layer and said polymer barrier layer. The closing lid is made of said at least one multilayer material further comprising said protective layer and said second adhesive layer.

In one embodiment, said first wall and said second wall are sealed with respect to each other and defining therebetween said inner volume, said first wall and said second wall being both made of the same compostable multilayer material.

This enables the formation of a symmetrical pod, easy to manufacture and to use. The user does not need to pay attention to the direction of introduction in the beverage machine. In one embodiment, said first wall and said second wall are both made of said at least one multilayer material comprising said paper layer, said first adhesive layer and said polymer barrier layer.

Brief description of the drawings

Additional features and advantages of the present invention are described in, and will be apparent from, the description of the presently preferred embodiments which are set out below with reference to the drawing in which:

Figure 1 is a perspective view of a pod according to one embodiment of the invention;

Figure 2 is a perspective cut-away view of the pod of figure 1; and

Figure 3 is a perspective view of a pod according to another embodiment of the invention.

Detailed description of the invention

Figures 1 and 2 illustrate a pod 1 according to one embodiment of the invention, and figure 3 illustrates a pod according to another embodiment of the invention.

The pod 1 has an inner volume in which a beverage ingredient is stored and in which a beverage is produced when water is introduced inside. The pod 1 comprises a first wall 11 through which water is to be introduced and a second wall 14 through which the beverage is to be dispensed.

The pod 1 represented at the figures is particularly designed to store coffee powder inside and produce a coffee beverage thanks to a dispensing machine. However the food or beverage ingredient can be of another type, for example a soluble food or beverage ingredient in liquid, semi-liquid, or powder form, either in infusable, extractable, or soluble form selected in the list of:

- Dairy powder or liquid concentrate (e.g. milk),

- Chocolate-based ingredients,

- Fruit powder,

- Fruit juice powder,

- Edible Soluble fibers,

- Leaf based plants (tea, mint, aromatic herbs, etc...),

- Roots (ginger, curcuma, etc...),

- Flavours,

- Vitamins,

- Minerals,

- Proteins,

- Probiotics, or a combination thereof.

The pod 1 is made of compostable materials. In particular, the pod 1 is "industrially" compostable or "home" compostable.

The pod 1 is thus made of one or several compostable multilayer materials. In other words, all the walls of the pod are made of the same compostable multilayer material, or different compostable multilayer materials are used for the walls of the pod.

The one or several multilayer materials comprise at least one paper layer and at least one polymer barrier layer.

The paper material for the paper layer can be elected depending on the desired mechanical properties.

The paper layer can be for example elected to be formable, i.e. stretchable. It can be mechanical or chemical paper. The paper layer is preferably made of Kraft paper. In addition to the mechanical properties of Kraft paper, it provides a visual aspect to the pod as being compostable due to the brown colour.

The paper layer can be food safe. For instance, the paper layer can be BFR-36.1 according to BFR Recommendations on Food Contact Materials.

The paper layer material can also be chosen to comply with some temperature requirements. For example, the paper layer can be elected to enable an extraction at hot temperatures (60°-100° C). Of course, the same paper material can be elected to enable utilisation for chilled-water extraction, or ambient-temperature water extraction or dissolution of the pod ingredient.

Preferably, the paper layer constitutes at least 50% of the one or several multilayer materials of the pod.

The paper layer can have a grammage for example between 40 and 150 gsm (gram per square meter). Preferably, the paper layer has a grammage of 60 gsm.

Polymer barrier layer shall be understood as a layer configured to protect the beverage ingredient in the pod, and provide a good shelf life, as well as a fresh and quality product in the cup for the consumer.

Preferably, the polymer barrier layer is a barrier to liquids, gas, in particular oxygen, and to moisture. This protection is important for the beverage ingredient, in particular for coffee which is very sensitive to oxidation and degradation by moisture.

The polymer barrier layer has a thickness comprised between 10 and 100 microns. Preferably, the thickness of the polymer barrier is comprised between 20 and 50 microns.

The thickness of the polymer barrier is designed to balance between the protection of the beverage ingredient in the pod and the resistance to piercing elements of the beverage preparation machine. Indeed, the polymer barrier layer should not be neither too difficult nor too easy to be pierced by the piercing elements.

Preferably, the polymer barrier layer is a plastic laminate.

The plastic laminate can comprise a Butenediol Vinyl Alcohol (BVOH) sheet sandwiched between two polymer sheets. The BVOH sheet is attached on both sides to the polymer sheets with tie sheets.

The polymer sheets comprise a mixture of polylactic acid (PLA), Polybutylene succinate (PBS) and polybutylene adipate terephthalate (PBAT).

The polymer sheets can be made of Ecovio ^® (available commercially from BASF, in particular Ecovio ^® 40 FS23N1 EXP).

In other embodiment, the polymer sheets can be starch based.

The BVOH sheet can be made of the Nichigo G-Polymer™

(Nippon Goshei).

A "tie sheet" refers to a polymer layer that bonds the polymer sheet to the BVOH sheet. A tie sheet is typically used to produce a material having at least three coextruded layers or sheets. The tie sheet can be made of an adhesive resin including anhydride-modified polymers resin, such as BTR-8002P (Nippon Gohsei).

The paper layer and the polymer barrier layer are attached to one another such as to present between them a bond strength at least equal to 1.6N / 15mm at 22°C, and 0.22 N /15mm at 100 °C according to the standard ASTM F904.

ASTM F904 is the international designation for the standard named "Standard Test Method for Comparison of Bond Strength or Ply Adhesion of Similar Laminates Made from Flexible Materials". As explained in this standard, "this test method covers a procedure for comparing the bond strength or ply adhesion of similar laminates made from flexible materials such as cellulose , paper plastic film , and foil. This includes laminates made by various processes: adhesive laminates , extrusion coatings , extrusion laminates , and coextrusion. " Minimum value of bond strength of l,6N/15mm shall be understood as measured under 22°C and 50% relative humidity which corresponds to the standard test conditions. As explained in the standard, the tests are conducted in the standard laboratory atmosphere of 23 ± 2°C (73.4 ± 3.6°F) and 50 ± 5 % relative humidity.

Minimum value of bond strength of 0.22 N /15mmshall be understood as measured under 100°C and 50% relative humidity.

Moreover, the values of the bond strength shall be understood as being measured with a machine having the parameters and settings presented in the standard. In particular, the jaw distance is of 25,4 mm and the test speed of 280mm/min ±10%.

Bonding strength is a key parameter to prevent delamination. Delamination can occur for various reasons, such as an overpressure within the pod. The overpressure can be built by degassing, i.e. by the production of gases by the beverage ingredient until its extraction from the pod, in other words during storage. Overpressure can also be the result of the variation of altitude. In particular the pod can be filled and sealed in a factory located at a certain altitude and then transported for sale and/or usage at a higher altitude.

A good bonding therefore ensures that the pod does not crack during storage if an overpressure occurs or if the pod is subject to any type of mechanical stress during storage.

In one embodiment, the paper layer and the polymer barrier layer are attached to one another by an adhesive layer.

Preferably, the adhesive layer covers a side of each of the paper layer and the polymer barrier layer.

The adhesive layer presents a homogenous thickness. In other words, there should be no excess or reduced thickness in the adhesive layer. This improves the bonding between the paper layer and the polymer barrier layer. Preferably, the adhesive layer presents a thickness between 1 and 20 microns.

Preferably, the adhesive layer presents a concentration of polyester-polyurethane elastomer in water . The adhesive layer is for example applied at an applied weight comprised between 2 and 15 g/m ² .

Preferably, the adhesive layer is made of Epotal ^® ECO 3702 (BASF). Epotal ^® ECO 3702 is an aqueous dispersion of a polyester-polyurethane elastomer. The PCT patent application published under the reference W02012/013506 discloses the composition of such an adhesive layer.

The adhesive layer can further comprise a hardener. A hardener can be used in particular for polymer dispersions. The hardener can be for example Basonat LR 9056.

For example, the adhesive layer comprises Epotal ^® ECO 3702 and Basonat LR 9056 added at a percentage between 1% and 10%, for example of 3%.

Other adhesives can be envisaged such as:

- BioTAK ^® S500 which is a water-borne adhesive based on a specially modified polyester copolymer;

- Morchem PS 255 ECO + CS-95 which is a Polyurethane Solvent based two-component adhesive;

- ADCOTE™ BL1001 Adhesive/BCR 1001 which is a two- component amorphous polymer;

- Scitech ST6093G and ST60097 which are water-borne two component adhesives;

- Epotal ^® P100 ECO Polyester-Polyurethane elastomer water borne two-component adhesive.

The one or several compostable multilayer materials can further comprise a protective layer of a polymeric compostable material. The protective layer prevents the paper from blocking the beverage machine. Indeed, small parts of paper can detach and block the beverage machine, and in particular the piercing elements.

The polymeric compostable material can be for example regenerated cellulose, in particular Cellophane™.

Preferably, the protective layer is water repellent.

The protective layer is attached to the other layers of the compostable multilayer material, and in particular to the paper layer with an adhesive layer. In other words, the one or several compostable multilayer materials further comprises a second adhesive layer to bond the protective layer and paper layer together.

The second adhesive layer can be the same as the adhesive layer described above and bonding together the paper layer and the polymer barrier layer.

The one or several multilayer materials can further comprise an ink printing on one of its surfaces. In particular, the one or several multilayer materials can further comprise an ink printing on the protective layer. The ink printing is preferably food safe.

Of course, the one or several multilayer materials can comprise an ink printing on layers other than the protective layer. The one or several multilayer materials can comprise an ink printing on the paper layer and/or on an external surface of the protective layer.

The ink printing can be for example an artwork printing for proper reading by the user of an information about the pod and/or the beverage ingredient.

The ink printing can also be an OID printing, i.e. an optical identification printing, which can be sensed by the beverage machine for automatic setting parameters or the like.

Of course the one or several multilayer materials can comprise a plurality and a variety of ink printings, for example both an artwork and an OID printings.

The use of regenerated cellulose as a protective layer when having an ink printing is advantageous, since cellulose possesses good printing qualities of printability, transparency and readability.

The following table provides an embodiment of a compostable multilayer material for the pod according to the invention. The first line of the table ("protective layer") corresponds to the outside layer of the pod, which is in contact with the outside atmosphere, whereas the last line of the table ("polymer barrier layer") corresponds to the innermost layer of the pod, which is in contact with the ingredient contained therein. The various lines provide the various layers, in order, from the outermost layer to the innermost layer of the pod wall.

The following tables provide more particular, i.e. specific, examples of possible compostable multilayer materials for the pod in which the materials for the different layers are referenced thanks to their commercial names as available on the market. The referenced layers in the following two tables correspond to particular examples of materials in the embodiment presented in the previous table. Compostable multilayer material 1:

Compostable multilayer material 2:

Of course, other combinations are also possible. Moreover, some layers, such as the protective layer and the printing can be removed or added. Moreover, in the provided examples, the polymer barrier multilayer is preferably symmetrically formed. In particular, the two polymer layers (Ecovio ^® in the examples above) are both similar. Similarly, the two tie layers (BTR-8002P in the examples above) are both similar. However, in another embodiment, the polymer barrier multilayer can comprise two different polymer layers, and/or two different tie layers.

As mentioned above, the pod 1 is made of one or several compostable multilayer materials. The one or several compostable multilayer materials can be chosen for example within the examples provided above in the tables "compostable material 1 or "compostable material 2". As described further, the pod 1 according to the embodiment of figures 1 and 2 comprises two different multilayer materials for its different walls, whereas the pod according to the embodiment of figure 3 is made of the same compostable multilayer material for all the pod walls. In any case, the pod can be either symmetrical or asymmetrical in its shape, independently of the composition of each of its walls.

In the embodiment represented in figures 1 and 2, the pod 1 comprises a body 10 and a closing lid 14. The closing lid 14 covers the body 10 so that the pod 1 is perfectly closed. The body 10 and the closing lid 14 form the inner volume in which the beverage ingredient is stored.

The body 10 has a three-dimensional shape. Three-dimensional shape shall mean that the body is "formed" or in other words that the body is not flat. The body 10 has a frustoconical shape extending around a revolution axis. The pod 1 is asymmetric with respect to a plane parallel to the closing lid 14.

The body 10 has a bottom wall 11 and a side wall 12. The side wall 12 can extend substantially perpendicularly to the bottom wall 11. The body 10 comprises a peripheral edge 13 surrounding the side wall 12. Preferably, the bottom wall 11, the side wall 12 and the peripheral edge 13 are made of a single piece.

The closing lid 14 is flat. The word "flat" shall mean that the closing lid 14 extends substantially in one plane. In other words, the closing lid 14 extends in one plane, but it can be deform in a convex or concave plane, depending on the relative pressure between the inside and the outside of the pod. In particular, it can happen that the ingredient contained therein (e.g. roast and ground coffee) will produce gases such as carbon dioxide over the storage period of the pod. In this case, an overpressure can be created within the pod, which forces the - initially flat - top lid to bulge outside. It can also happen that the atmospheric pressure varies around the pod, for instance if the pod is formed, filled and sealed at a factory which is near sea level, and then said pod is transported at a higher altitude, where the atmospheric pressure is lower. In such case, the - initially flat - top lid will deflect inwardly in a concave shape. The closing lid 14 is sealed on the body 10. In the described embodiment, the closing lid 14 is sealed on the peripheral edge 13. The closing lid 14 fits closely the body 10 so that a perfect sealing of the pod 1 is ensured.

Preferably, the body 10 is made of a first compostable multilayer material and the closing lid 14 is made of a second compostable multilayer material.

The first compostable multilayer material of the body 10 is preferably at the same time a material that allows a proper opening by piercing elements of the beverage machine and a stretchable material.

Indeed, during beverage production in a machine, water is introduced through the body 10. Water is injected though the bottom wall 11, which forms the first wall as defined above or injection side. For a good quality extraction of the beverage ingredient, in particular of coffee, it was found that the opening of the pod 1 by means of needles of the machine must be smooth and easy. Furthermore, the body 10 is formed starting from a flat blank which is stretched and given a shape. Using stretchable materials for the body 10 allows the required stretching during the formation of the body, without breaking or tearing. Moreover, thanks to stretchable materials it is possible to give the desired shape and dimensions to the body 10. For instance, the more the material is stretchable, the more it is possible to elongate the body and extend the dimensions of the body.

In this embodiment, these properties of the pod body 10 are provided by the compostable multilayer material 1 presented in the table above. Of course, in other embodiments, the layers can replaced by other materials, in particular from those described and presented in this document.

The second compostable multilayer material of the closing lid is preferably a material enabling an instantaneous or snapping rupture with a small elongation.

During beverage production in a machine, the beverage is dispensed through the closing lid 14 which forms the second wall as define above. Following the injection of water inside the pod, water pressure builds inside the pod, provoking swelling of the ingredient, and expansion of the internal volume of the pod. The dispensing side (i.e. the closing lid 14) of the pod 1 is thus pressed against a dispensing structure of the machine. The closing lid is pierced for example by means of truncated pyramids of the machine.

For proper opening of the pod, and good of the beverage ingredient, in particular of coffee, it was found that the opening of the dispensing side, here the closing lid, should be realised in an instant, as a result of a snapping rupture. The closing lid should tear but not elongate at the piercing.

These properties of the closing lid 14 are provided by the multilayer material 2 presented above in the table above. Of course, in alternative embodiments, the layers of can replaced by other materials, chosen from those described and presented in this document.

In the embodiment of figure 3, the pod 1 comprises a first wall 11 and a second wall 14. The first wall 11 and said second wall 14 are sealed with respect to each other and define therebetween the inner volume.

The pod 1 presents the form of a macaroon. The bisector plane of the gravity points of the first wall 11 and the second wall 14 is thus also a bisector plane of the pod 1. The first wall 11 and the second wall 14 can be identical to each other, in shape and composition. In particular, the first wall 11 and the second wall 14 are both made of the same compostable multilayer material.

Preferably, the compostable multilayer material of the pod 1 presents the same properties as the first material of the body 10 in the previously described embodiment with reference to figures 1 and 2. In other words, the compostable multilayer material in which is made the pod 1 of figure 3 is for example one of the compostable multilayer material 1 presented in the table above. The invention proposes thus a compostable pod having interesting mechanical properties, in particular with respect to conservation during storage, resistance to mechanical stress, and formability.

Of course, in an alternative, there can be some differences between the compositions of the compostable multilayer materials of each of the first wall 11 and the second wall 14.

It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be covered by the appended claims.