METHODS AND DEVICES USING REVERSIBLY REMOVABLE TEETH TO DISPENSE A MATERIAL SUCH AS A BEVERAGE POWDER

BACKGROUND

[0001] The present disclosure relates generally to devices and methods for dispensing a material such as a beverage powder. More specifically, the present disclosure is directed to powder dispensing devices having a reversibly removable rail comprising teeth, and the present disclosure is also directed to methods for making and using such devices.

[0002] Powders can be used to prepare beverages, particularly hot beverages such as coffee, tea or hot chocolate. Such powders are typically prepared commercially by drying granular material containing the beverage ingredients. However, handling of the material on an industrial scale may be difficult because the material forms clumps or piles or otherwise attaches to each other and/or the processing equipment. This problem occurs even more frequently in regions with high humidity because moisture encourages agglomeration of the granules. As a result, granules can remain inside the processing equipment and thereby not reach the area where they would be dried. Furthermore, the retained granules can affect the dispensing of subsequent granules.

SUMMARY

[0003] The present inventors employed beverage ingredient granules, such as frozen coffee granules, in a process in which the granules travel from a hopper to a feeder chute. The granules fall from the feeder chute into a tray in which the granules are dried, e.g., by a vacuum dryer. A vibratory motor is attached to the bottom of the hopper. The vibratory motor turns on and off when filling individual trays. When the vibratory motor turns on, it shakes the granules out of the hopper, and the feeder chute directs the granules to the tray through a waterfall effect. The feeder chute has a slot opening, and the present inventors recognized that the slot opening could be improved to uniformly fill the tray.

[0004] Specifically, the present inventors recognized that consistency and uniformity of the tray filling is critical to the final product output and quality. For example, the present inventors found that the front-to-back filling of the tray is controlled by the speed of the conveyor on which the tray is positioned, the speed of the vibrating device, and other automated functions; but the side -to-side filling of the tray is more difficult to perform uniformly. If the tray is not filled uniformly across the width of the tray, this non-uniformity causes uneven drying of the product in the tray and affects the final product quality and output. The quality can be affected in two ways, namely increased rework and uneven final moisture. Achieving uniform distribution would increase product weight in the tray, increase the final moisture due to more consistent drying, reduce the rework, and thus provide better efficiency.

[0005] Therefore, the present inventors examined their production process more closely. The slot opening in the feeder chute has adjustable teeth that assist in distributing the product evenly across the width of the tray. The present inventors found that the teeth become dirty such that the distribution of the granular material is changed after one to two days of production. The normal production cycle can be 21 -28 days, thus most of the production cycle would be performed with uneven distribution. The teeth are not easily accessible, and typically two maintenance personnel would spend eight hours to remove the feeder chute, clean it and then reconnect it to the hopper. For example, when frozen coffee granules were processed, ice and coffee would need to be cleaned from the teeth which are fixed to the device. Moreover, some processes involve cold temperatures such as -40 °C in which the endeavor of removing and cleaning the equipment is burdensome.

[0006] Accordingly, in a general embodiment, the present disclosure provides a dispensing device comprising: a hopper configured to hold a material therein; a feeder chute positioned under the hopper; and a rail connected to the feeder chute, comprising one or more teeth, and reversibly removable from the feeder chute.

[0007] In an embodiment, the feeder chute comprises a bottom wall, and the one or more teeth and the bottom wall form at least part of a slot in the feeder chute.

[0008] In an embodiment, the feeder chute comprises a side wall comprising an aperture sized and shaped for the rail to be removed from the feeder chute and reconnected to the feeder chute therethrough.

[0009] In an embodiment, the dispensing device comprises a guide post configured to position the rail within the feeder chute. The guide post can be movably connected to a side wall of the feeder chute such that a height of the guide post in the feeder chute is selectively adjustable. The guide post can position the rail approximately parallel to a bottom wall of the feeder chute. The guide post can comprise a first connector, the feeder chute can comprise a second connector, and the first connector can be configured to attach to the second connector. The dispensing device can comprise an additional guide post configured to position the rail within the feeder chute, wherein the guide post abuts a top surface of the rail, and the additional guide post can abut a bottom surface of the rail.

[0010] In another embodiment, the present disclosure provides a method of processing a material stored in a hopper positioned above a feeder chute. The method comprises: positioning a tray under the feeder chute; and dispensing the material from the hopper to the feeder chute and then through a slot in the feeder chute onto the tray, the slot formed at least in part by one or more teeth provided by a rail that is reversibly removable from the feeder chute.

[0011] In an embodiment, the method comprises removing the rail from the feeder chute, then cleaning the one or more teeth, and then reconnecting the rail to the feeder chute. The removing of the rail can comprise sliding the rail out of the feeder chute through an aperture in the feeder chute, and the reconnecting of the rail comprises sliding the rail into the feeder chute through the aperture.

[0012] In an embodiment, the method comprises selectively adjusting the height of the one or more teeth in the feeder chute to a desired height.

[0013] In an embodiment, the rail comprises a beam to which the one or more teeth are movably attached, and the adjusting comprises selectively moving the one or more teeth upward or downward relative to the beam.

[0014] In an embodiment, the rail comprises a beam to which the one or more teeth are movably attached, the beam is movably attached to the feeder chute, and the adjusting comprises selectively moving the beam upward or downward relative to the feeder chute. The moving of the beam upward or downward relative to the feeder chute can comprise selectively moving one or more guide posts connected to the feeder chute upward or downward relative to the feeder chute, and the one or more guide posts can be configured for the beam to be attached to and reversibly removable from the one or more guide posts. The method can comprise reversibly attaching a first connector provided by the guide post to a second connector provided by the feeder chute.

[0015] In another embodiment, the present disclosure provides a method of cleaning a dispensing device comprising a hopper, a feeder chute, and a rail comprising one or more teeth that form at least part of a slot in the feeder chute. The method comprises: removing the rail from a first position in the feeder chute; then cleaning the one or more teeth; and then reconnecting the rail to the feeder chute.

[0016] In an embodiment, the reconnecting of the rail comprises a step selected from the group consisting of (i) returning the rail to the first position and (ii) connecting the rail to the feeder chute at a second position vertically aligned with the first position but at a different height in the feeder chute relative to the first position.

[0017] In an embodiment, the removing of the rail comprises sliding the rail out of the feeder chute through an aperture in a side wall of the feeder chute, and the reconnecting of the rail to the feeder chute comprises sliding the rail into the feeder chute through the aperture.

[0018] In an embodiment, the removing of the rail comprises sliding the rail out of the feeder chute along one or more guide posts connected to the feeder chute, and the reconnecting of the rail to the feeder chute comprises sliding the rail into the feeder chute along the one or more guide posts.

[0019] An advantage of one or more embodiments provided by the present disclosure is to dispense a granular material using a hopper that has a feeder chute in which teeth are reversibly removable through the side of the feeder chute.

[0020] Another advantage of one or more embodiments provided by the present disclosure is to reduce the time of cleaning of a hopper-based dispensing device from a time period of about eight hours to a time period of about thirty minutes.

[0021] A further advantage of one or more embodiments provided by the present disclosure is to uniformly distribute a granular material in a tray.

[0022] Yet another advantage of one or more embodiments provided by the present disclosure is to minimize the time an individual must be in a cold environment during a cleaning operation.

[0023] Another advantage of one or more embodiments provided by the present disclosure is to improve efficiency of a powder-processing operation.

[0024] A further advantage of one or more embodiments provided by the present disclosure is to increase the amount of throughput of a powder-processing operation.

[0025] Additional features and advantages are described herein and will be apparent from the following Detailed Description and the Figures. BRIEF DESCRIPTION OF THE FIGURES

[0026] FIG. 1 shows an embodiment of a beverage powder processing system provided by the present disclosure.

[0027] FIG. 2 shows a side perspective view of an embodiment of a feeder chute provided by the present disclosure.

[0028] FIG. 3 shows a side perspective view of an embodiment of a reversibly removable rail comprising teeth that is provided by the present disclosure.

[0029] FIG. 4 shows a side perspective view of a reversibly removable rail comprising teeth that is connected to a feeder chute in an embodiment provided by the present disclosure.

[0030] FIG. 5 shows a side perspective view of a reversibly removable rail comprising teeth that is connected to a feeder chute in an embodiment provided by the present disclosure, from the opposite lateral side relative to FIG. 4.

[0031] FIG. 6 shows an underneath perspective view of a reversibly removable rail comprising teeth that is connected to a feeder chute in an embodiment provided by the present disclosure.

[0032] FIG. 7 shows an underneath perspective view of a reversibly removable rail comprising teeth that is connected to a feeder chute in an embodiment provided by the present disclosure, from the opposite lateral side relative to FIG. 6.

[0033] FIG. 8 shows a side perspective view of a reversibly removable rail comprising teeth that is partially inserted into or removed from a feeder chute in an embodiment provided by the present disclosure.

[0034] FIG. 9 shows a side perspective view of a reversibly removable rail comprising teeth that is partially inserted into or removed from a feeder chute in an embodiment provided by the present disclosure, from the opposite lateral side relative to FIG. 8.

[0035] FIG. 10 shows a close-up perspective view of an aperture in a feeder chute in which a reversibly removable rail comprising teeth can be inserted or removed, in an embodiment provided by the present disclosure.

[0036] FIG. 11 shows the design of the experimental study disclosed herein.

[0037] FIG. 12 is a graph showing results from the experimental study disclosed herein. DETAILED DESCRIPTION

[0038] As used in this disclosure and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a powder" or "the powder" includes two or more powders.

[0039] The words "comprise," "comprises" and "comprising" are to be interpreted inclusively rather than exclusively. Likewise, the terms "include," "including" and "or" should all be construed to be inclusive, unless such a construction is clearly prohibited from the context.

[0040] Nevertheless, the devices and apparatuses disclosed herein may lack any element that is not specifically disclosed. Thus, a disclosure of an embodiment using the term "comprising" includes a disclosure of embodiments "consisting essentially of and "consisting of the components identified. Similarly, the methods disclosed herein may lack any step that is not specifically disclosed herein. Thus, a disclosure of an embodiment using the term "comprising" includes a disclosure of embodiments "consisting essentially of and "consisting of the steps identified.

[0041] The term "and/or" used in the context of "X and/or Y" should be interpreted as "X," or "Y," or "X and Y." Where used herein, the terms "example" and "such as," particularly when followed by a listing of terms, are merely exemplary and illustrative and should not be deemed to be exclusive or comprehensive. Any embodiment disclosed herein can be combined with any other embodiment disclosed herein unless explicitly stated otherwise.

[0042] As used herein, "uniform" or "even" distribution means that the height of the top of the distributed material is approximately the same at all locations where the material is distributed. As used herein, "about" and "approximately" are understood to refer to numbers in a range of numerals, for example the range of -10% to +10% of the referenced number, preferably within -5% to +5% of the referenced number, more preferably within -1% to +1% of the referenced number, most preferably within -0.1 % to +0.1 % of the referenced number. As a non- limiting example, a material distributed into a tray to form a layer having a height of 36-38 mm throughout the entirety thereof is a particularly preferred embodiment having uniform distribution.

[0043] As used herein, "reversibly removable," "reversibly attached" and "reversibly connected" mean that the referenced components can be connected to and removed from each other without damaging any of the referenced components and without damaging a connector, if any. "Selectively moving" and "selecting adjusting" mean that the referenced component is moved to a desired position by a human or by a tool controlled by a human and does not encompass movement of the referenced component due its involvement in the processing operation. For example, "selectively moving" and "selecting adjusting" do not encompass movement from shaking or vibrating during processing of the material.

[0044] As shown in FIG. 1, an aspect of the present disclosure is a dispensing device 10 comprising a hopper 11 and a feeder chute 12 at the bottom of the hopper 1 1. The hopper 11 can be any container suitable for holding a material 100 therein, for example a granular material comprising one or more beverage ingredients. The hopper 11 can have a lower opening directed to the feeder chute 12.

[0045] As shown in FIGS. 2 and 4-10, the feeder chute 12 can have a bottom wall 12a, a first side wall 12b, a second side wall 12c, and a back wall 12d fixedly connected to each other. The feeder chute 12 can comprise an opening 14 that can be positioned opposite to the back wall 12d. The material 100 positioned in the hopper 1 1 can be directed onto the bottom wall 12a of the feeder chute 12 and then through the opening 14 onto a tray 20 positioned underneath the dispensing device 10.

[0046] Referring again to FIG. 1, the dispensing device 10 can comprise a vibrating device 13 that may be any apparatus configured to vibrate at least one of the hopper 1 1 or the feeder chute 12. Preferably the vibrating by the vibrating device 13 can urge the material 100 from the hopper 1 1 into the feeder chute 12 and/or from within the feeder chute 12 through the opening 14 into the tray 20.

[0047] As shown in FIGS. 3-9, a rail 30 can be reversibly removable from the feeder chute 12. Preferably the rail 30 is adjacent to the opening 14 when connected to the feeder chute 12. The rail 30 can be approximately horizontal when connected to the feeder chute 12 and/or can be approximately parallel to the opening 14 when connected to the feeder chute 12.

[0048] In a preferred embodiment, the rail 30 comprises a beam 31 and one or more teeth 32 extending from the beam 31. Each of the one or more teeth 32 can be any structure that defines at least part of a slot 33 by which the material 100 from the hopper 1 1 reaches the opening 14, such as teeth, plates or blades for example (e.g., fiat plates or blades). In an embodiment, the one or more teeth 32 can form the top of the slot 33; the side walls 12b, 12c of the feeder chute 12 can form the sides of the slot 33; and the bottom wall 12a of the feeder chute 12 can form the bottom of the slot 33. The slot 33 can ensure uniform distribution of the material 100 from the feeder chute 12 into the tray 20. Preferably the lower edge of the one or more teeth 32 is approximately parallel to the bottom wall 12a of the feeder chute 12.

[0049] The rail 30 preferably has a length at least as large as the distance from the first side wall 12b to the second side wall 12c, and in an embodiment the rail 30 has a length about the same as the distance from the first side wall 12b to the second side wall 12c. For example, the beam 31 can have a length at least as large as the distance from the first side wall 12b to the second side wall 12c, such as about the same as the distance from the first side wall 12b to the second side wall 12c.

[0050] The one or more teeth 32 can be reversibly removable from the beam 31. A non- limiting example of this configuration is shown in FIGS. 3-9 in which the one or more teeth 32 are connected to the beam 31 by one or more bolts 34.

[0051] The distance that the one or more teeth 32 extend from the beam 31 can be selectively adjusted to thereby adjust the height of the slot 33 and consequently the height of the material 100 distributed onto the tray 20. For example, the one or more teeth 32 can be selectively moved up on the beam 31 to decrease the distance that the one or more teeth 32 extend from the beam 31, increase the height of the slot 33, and increase the height of the material 100 distributed onto the tray 20. As another example, the one or more teeth 32 can be selectively moved down on the beam 31 to increase the distance that the one or more teeth 32 extend from the beam 31, decrease the height of the slot 33, and decrease the height of the material 100 distributed onto the tray 20.

[0052] As shown in FIGS. 2 and 4-10, the feeder chute 12 can have a structure configured for the rail 30 to be reversibly removable from the feeder chute 12. For example, the feeder chute 12 can have an aperture 12e in at least one of the first and second side walls 12b, 12c, and the rail 30 can insert through the aperture 12e. FIGS. 2, 4 and 8-10 show the aperture 12e positioned in the first side wall 12b, but the aperture 12e can be alternatively or additionally positioned in the second side wall 12c (e.g., each of the first and second side walls 12b, 12c can have an aperture therein). The aperture 12e preferably has a shape that is about the same as the cross-sectional shape of the rail 30 and preferably has a size so that the rail 30 in its entirety can travel through the aperture 12e. In an embodiment, the aperture 12e can be closed when the rail 30 is fully positioned within the feeder chute 12, for example closed by a reversibly removable plate 12f. [0053] The rail 30 can be positioned within the feeder chute 12 by one or more guide posts 15 that can extend from the first side wall 12b to the second side wall 12c. When the rail 30 is inserted or removed from the feeder chute 12, the rail 30 can abut the one or more guide posts 15. For example, the beam 31 can abut the one or more guide posts 15 when the rail 30 is inserted or removed from the feeder chute 12. In a preferred embodiment, the beam 31 is received by the one or more guide posts 15 in a friction fit such that an upper guide post 15a abuts the top of the beam 31 and a lower guide post 15b abuts the bottom of the beam 31. The dispensing device 10 is not limited to a specific embodiment of the connection between the beam

31 and the one or more guide posts 15, and any connection known to the skilled artisan can be employed.

[0054] The distance of the one or more guide posts 15 from the bottom wall 12a of the feeder chute 12 can be selectively adjusted to thereby adjust the distance of the one or more teeth 32 from the bottom wall 12a of the feeder chute 12. For example, the one or more guide posts 15 can insert through one or more channels 16. The one or more channels 16 can be formed in the first side wall 12b and/or the second side wall 12c. The one or more guide posts 15 can be selectively moved up in the channels 16 so that the rail 30, when connected to the one or more guide posts 15, is a greater distance from the bottom wall 12a of the feeder chute 12. The one or more guide posts 15 can be selectively moved down in the channels 16 so that the rail 30, when connected to the one or more guide posts 15, is a smaller distance from the bottom wall 12a of the feeder chute 12.

[0055] The distance of the one or more guide posts 15 can be selectively adjusted to thereby adjust the height of the slot 33 and consequently the height of the material 100 distributed from the feeder chute 12 into the tray 20. For example, the one or more guide posts 15 can be selectively moved up in the channels 16 to increase the distance from the one or more teeth 32 to the bottom wall 12a, increase the height of the slot 33, and increase the height of the material 100 distributed onto the tray 20. As another example, the one or more guide posts 15 can be selectively moved down in the channels 16 to decrease the distance from the one or more teeth

32 to the bottom wall 12a, decrease the height of the slot 33, and decrease the height of the material 100 distributed onto the tray 20.

[0056] In an embodiment, the one or more guide posts 15 can comprise a first connector 41; the feeder chute 12 can comprise a second connector 42 that cooperatively interacts with the first connector 41 ; and the first and second connectors 41 ,42 can maintain the position of the one or more guide posts 15 in the feeder chute 12, as shown in FIG. 10. Preferably the first and second connectors 41,42 can be used to selectively adjust the distance of the one or more guide posts 15 from the bottom wall 12a.

[0057] For example, the first connector 41 can comprise a first flange and can comprise a bolt (e.g., extending from the first flange), and the second connector 42 can comprise a second flange and can comprise a hole (e.g., through the second flange). The distance that the bolt extends through the hole can establish the distance of the one or more guide posts 15 from the bottom wall 12a. A fastener connected to the bolt and/or the second flange can maintain the position of the bolt in the hole.

[0058] In another aspect, the present disclosure provides a method of processing a material, for example a beverage powder, that is stored in a hopper positioned above a feeder chute. The method can comprise one or more of: (i) indexing an empty tray on a conveyor; (ii) positioning the tray under the feeder chute, for example by moving the tray on the conveyor; (iii) initiating operation of a vibrating device connected to the dispensing device; and (iv) dispensing the material from the hopper to the feeder chute and then through a slot in the feeder chute onto the tray, the slot formed in part by one or more teeth provided by a rail that is reversibly removable from the feeder chute. The method can comprise drying the material in the tray. The method can use any embodiment of the dispensing device 10 disclosed herein or any other dispensing device capable of performing the steps of the method.

[0059] In an embodiment, the method comprises selectively adjusting the height of the one or more teeth in the feeder chute to a desired height. The adjusting can comprise selectively moving the one or more teeth upward or downward relative to a beam of the rail, and the one or more teeth are movably attached to the beam. Additionally or alternatively, the adjusting can comprise selectively moving a beam of the rail upward or downward relative to the feeder chute, the one or more teeth are attached to the beam, and the beam is movably attached to the feeder chute. The moving of the beam upward or downward relative to the feeder chute can comprise moving one or more guide posts connected to the feeder chute upward or downward relative to the feeder chute. The method can comprise connecting the rail to the one or more guide posts before and/or during and/or after the moving of the one or more guide posts upward or downward relative to the feeder chute. In an embodiment, the method comprises positioning the rail at the desired height in the feeder chute and comprises connecting a first connector provided by the one or more guide posts to a second connector provided by the feeder chute to maintain the desired height of the rail.

[0060] In yet another aspect, the present disclosure provides a method of cleaning a dispensing device comprising a hopper, a feeder chute, and a rail comprising one or more teeth that form at least part of a slot in the feeder chute. Preferably at least one of a bottom wall, a first side wall, and a second side wall of the feeder chute also form the slot. The method can comprise removing the rail from a first position in the feeder chute, then cleaning the one or more teeth, and then reconnecting the rail to the feeder chute. In an embodiment, the rail is reconnected in the first position. In another embodiment, the rail is reconnected in a second position vertically aligned with the first position but at a different height in the feeder chute relative to the first position (e.g., a desired height selected by a user). The method can use any embodiment of the dispensing device 10 disclosed herein or any other dispensing device capable of performing the steps of the method.

[0061] The removing of the rail can comprise sliding the rail out of the feeder chute through an aperture in a side wall of the feeder chute, and/or the reconnecting of the rail to the feeder chute can comprise sliding the rail into the feeder chute through the aperture. In an embodiment, the reconnecting of the rail can comprise reversibly attaching the rail to one or more guide posts connected to the feeder chute. The cleaning of the one or more teeth can comprise removing a material from the one or more teeth, for example ice and/or a powder such as a beverage powder.

[0062] In yet another aspect, the present disclosure provides a method of making a dispensing device. The method comprises connecting a hopper to a feeder chute. The method further comprises connecting a rail comprising one or more teeth to the feeder chute, and the connecting of the rail to the feeder chute forms a slot in the feeder chute and configures the rail to be reversibly removable from the feeder chute. The rail can be reversibly connected to the feeder chute before the feeder chute is connected to the hopper or after the feeder chute is connected to the hopper. Preferably at least one of a bottom wall, a first side wall, and a second side wall of the feeder chute also form the slot. The method can make one or more embodiments of the dispensing device 10 disclosed herein.

[0063] The connecting of the rail to the feeder chute can comprise sliding the rail into the feeder chute through an aperture in a side wall of the feeder chute. The method can comprise connecting one or more guide posts to the feeder chute, the one or more guide posts are configured for the rail to be attached to and reversibly removable from the one or more guide posts, and the guide posts are attached to the feeder chute in a configuration such that the one or more guide posts position the rail in the feeder chute. In an embodiment, the connecting of the one or more guide posts to the feeder chute can comprise attaching a first connector provided by the one or more guide posts to a second connector provided by the feeder chute.

[0064] EXAMPLE

[0065] The following non-limiting example details experimental evidence related to the cleaning of the one or more teeth.

[0066] As shown in FIG. 11, the tray was divided into fifteen equally-sized zones covering the entire width and length of the tray, and the height of the powder in the tray was measured immediately before cleaning of the teeth and then two days after cleaning of the teeth. A rating was given to each zone based on the level of the powder.

[0067] FIG. 12 shows the results. The data shows the significance of keeping the teeth clean. With a design in which the teeth are positioned on a rail which is not removable, removing and cleaning the teeth every two days is operationally inefficient. Specifically, this would equate to 24 hours of downtime per week. The removable rail design would eliminate these maintenance requirements, reducing the downtime from two people for eight hours to one person for thirty minutes. In addition, keeping the teeth clean will provide a consistent distribution of product out of the hopper. This consistent distribution allows the operators to increase the weight in the trays, resulting in higher production output, higher final product moisture, and more consistent product moisture. [0068] 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 subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.