Mi l l) OF THE INVENTION:

The invention generally relates to process and system of producing dry aroma vapours from wet aroma vapours. The invention further relates to producing aroma containing soluble powders using dry aroma vapours. The invention furthermore relates to producing aroma enriched soluble powders using dry aroma vapours. In particular, the present invention relates to a process and system for producing dry aroma vapours, aroma containing soluble powders and aroma enriched soluble powders of coffee, tea, fruits and vegetables.

BACKGROUND OF THE INVENTION:

Aromas are an important part of many soluble powders such as soluble coffee powders, soluble tea powders, soluble fruit powders, soluble vegetable powders, etc., (which are being commonly referred to as “aroma containing soluble powders”).

A first reported and widely followed process for preparing aroma containing soluble powders includes (a) obtaining an extract comprising aroma constituting components, (b) processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components and the wet aroma vapours comprise aroma constituting components and moisture, (c) subjecting the mother liquor to concentration to obtain a decoction, (d) condensing the entire volume of wet aroma vapours to obtain dilute aroma liquid, and (e) mixing the dilute aroma liquid with the decoction and feeding the mixture to a drier thereby obtaining aroma containing soluble powders.

A second reported process, as discussed in WO 1996/033622, for preparing aroma containing soluble powders includes (a) obtaining an extract comprising aroma constituting components, (b) processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components and the wet aroma vapours comprise aroma constituting components and moisture, (c) subjecting the mother liquor to concentration to obtain a decoction, (d) converting the wet aroma vapours into dry aroma vapours, (e) condensing the dry aroma vapours to obtain concentrated aroma liquid, and (f) mixing the concentrated aroma liquid with the decoction and feeding the mixture to a drier thereby obtaining aroma containing soluble powders. In this process, the wet aroma vapours are made to pass through one or more condensers operated at a temperature which is supposed to cause condensation of moisture but not condensation or freezing of the aroma constituting components, thereby producing dry aroma vapours. Temperatures in the region of 0°C to 20°C are commonly used. Thereafter, the entire volume of dry aroma vapours is condensed to obtain concentrated aroma liquid. It has however been observed that this technique removes many aroma constituting components as originally present in the wet aroma vapours and hence, is not extensively followed.

A third reported process, as disclosed in U.S. Patent 5,342,639, for preparing aroma containing soluble powders includes (a) obtaining an extract comprising aroma constituting components, (b) processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components and the wet aroma vapours comprise aroma constituting components and moisture, (c) subjecting the mother liquor to concentration to obtain a decoction, (d) converting the wet aroma vapours into dry aroma vapours, (e) condensing the dry aroma vapours to obtain concentrated aroma liquid, and (f) mixing the concentrated aroma liquid with the decoction and feeding the mixture to a drier thereby obtaining aroma containing soluble powders. As per this document, the wet aroma vapours are made to pass through a desiccant bed containing calcium sulphate granules that selectively absorbs moisture, thereby producing dry aroma vapours. Thereafter, the entire volume of dry aroma vapours is condensed to obtain concentrated aroma liquid. The desiccant bed loses its capacity to absorb moisture over a period of time and has to be regenerated periodically. The capacity of this process is low, the process is energy-intensive and excess pressure drops are observed across the desiccant bed (which leads to complications in downstream processing). Hence, this technique is also not extensively followed by the industry.

A fourth reported process, as disclosed in WO 1996/033622, for preparing aroma containing soluble powders includes (a) obtaining an extract comprising aroma constituting components, (b) processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components and the wet aroma vapours comprise aroma constituting components and moisture, (c) subjecting the mother liquor to concentration to obtain a decoction, (d) converting the wet aroma vapours into partially dry aroma vapours, (e) converting the partially dry aroma vapours into dry aroma vapours, (f) condensing the dry aroma vapours to obtain concentrated aroma liquid, and (g) mixing the concentrated aroma liquid with the decoction and feeding the mixture to a drier thereby obtaining aroma containing soluble powders. As per this document, the wet aroma vapours are made to pass through one or more bed comprising molecular sieves containing A - Type Zeolite to produce the partially concentrated aroma vapours. The partially concentrated aroma vapours are made to pass through one or more condensers operated at a temperature which is supposed to cause condensation of moisture but not condensation or freezing of the aroma constituting components, thereby producing dry aroma vapours. Thereafter, the entire volume of dry aroma vapours is condensed to obtain concentrated aroma liquid. It has been observed that this technique removes many aroma constituting components as originally present in the wet aroma vapours. Furthermore, two devices are needed to obtain the dry aroma vapours, which tend to increase the cost and complexity of the operation.

It has been observed that obtaining the aroma containing soluble powders from a mixture comprising decoction and dilute aroma liquid (as in the first reported process) or a mixture comprising decoction and concentrated aroma liquid (as in the second to the fourth reported processes) presents problems in start-up and stopping operations, adjustments of the spray nozzles in the drier, clogging of the spray nozzles in the drier, substantial loss of the aroma constituting elements. The substantial loss in the aroma constituting elements is in addition to the removal of many aroma constituting components as originally present in the wet aroma vapours.

Thus, a fifth reported process which produces aroma enriched soluble powders includes (a) obtaining an extract comprising aroma constituting components, (b) processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components and the wet aroma vapours comprise aroma constituting components and moisture, (c) subjecting the mother liquor to concentration to obtain a decoction, (d) obtaining concentrated aroma liquid from wet aroma vapours, (e) feeding the decoction to a drier thereby obtaining aroma soluble powders that are devoid of aroma, and (f) aromatizing the soluble powders that are devoid of aroma using the concentrated aroma liquid thereby obtaining aroma enriched soluble powders.

A typical apparatus for aromatizing the soluble powders as disclosed in U.S. Patent No. 3,148,070 comprises a tube supplying coffee powders, a conical distributing surface disposed at the lower end of the tube with its pointed end facing upwards for producing an annular powder curtain; the conical distributing surface and the tube are disposed so as to have a common vertical axis, and a spray nozzle located underneath the conical distributing surface for spraying the aromatizing liquid on to the annular powder curtain. U.S. Patent No. 3,077,405 discloses a process for preparing an aromatized, free-flowing soluble coffee which comprises passing particles of soluble coffee through a moving contact zone, plating onto the surface of said particles in said contact zone droplets of an aromatizing coffee oil, controlling the ratio of coffee oil droplets to coffee particles so that less than all of the coffee particles are wet by the coffee oil, continually contacting said wetted particles of coffee with other particles of coffee thereby producing agglomerates of coffee particles, continually introducing soluble coffee particles to said contact zone to continue the production of said agglomerates in said zone, and create micro heterogeneous distribution of said agglomerates after they have been contacted by said oil, and withdrawing from said zone aromatized mechanically stable, free-flowing soluble coffee containing aromatized agglomerates, the agglomerate phase of the mixture constituting a minor portion of the volume of the total coffee product.

Yet another apparatus for aromatizing as disclosed in U.S. Patent No. 4,355,571 comprises a circular member mounted for rotation in an assembly which includes a material in-feed chute and a material discharge chute, said member containing at least one peripheral groove of uniform cross-section disposed to receive material from said in-feed chute, said member while rotating carrying a ribbon of said material within the confines of said groove from said in-feed to said discharge chute, an injector member disposed to continually dispense said liquid into said ribbon carried from said in-feed to said discharge chute, and a pump member in liquid communication with said injector and driven in synchronism with said circular member for supplying said injector with said liquid at a predetermined weight ratio to the material discharged by said circular member.

Despite the presence of a variety of processes and a variety of systems for producing aroma incorporated soluble powders, it has been observed that only low quantities of aroma are being incorporated in soluble powders and that many aroma constituting components as originally present in the wet aroma vapours are lost. The loss of the aroma constituting components lead to un-even tone of the aroma containing soluble powders. Apart from the above disadvantage, the construction of the system is complicated and has large number of components, due to which, the cost of the system increases substantially.

Thus, there exists a need to provide a process and a system of producing dry aroma vapours from wet aroma vapours that addresses the disadvantage as faced in the prior art. Further, there exists a need to provide a process and a system for producing aroma containing soluble powders using dry aroma vapours that addresses the disadvantages as faced in the prior art. Furthermore, there exists a need to provide a process and a system for producing aroma enriched soluble powders using dry aroma vapours that addresses the disadvantages as faced in the prior art.

SUMMARY OF THF. TNVF.NTTON:

This summary is provided to introduce a selection of concepts in a simplified format that is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor is it intended for determining the scope of the invention.

Accordingly, the present invention provides a process for producing dry aroma vapours from wet aroma vapours by removing moisture contained in the wet aroma vapours. The process comprises condensing the wet aroma vapours to obtain a first liquid stream, the first liquid stream comprising aroma constituting components and water. The process further comprises bringing the first liquid stream in contact with a bed comprising zeolite so as to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce the dry aroma vapours. In an embodiment of the invention, bringing the first liquid stream in contact with a bed comprising zeolite comprises controlling a temperature of the zeolite bed such that selective vaporization of the aroma constituting components occurs and vaporization of water is avoided.

In another aspect of the invention, there is provided a process of producing aroma containing soluble powders. The process of producing aroma containing soluble powders comprises obtaining an extract comprising aroma constituting components. The process further comprises processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components while the wet aroma vapours comprises aroma constituting components and moisture. The process further comprises condensing the wet aroma vapours to obtain a first liquid stream, the first liquid stream comprising aroma constituting components and water. The process further comprises bringing the first liquid stream in contact with a bed comprising zeolite so as to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce dry aroma vapours. The process further comprises subjecting the dry aroma vapours to condensation to obtain concentrated aroma liquid. The process further comprises concentrating the mother liquor to obtain a decoction. The process further comprises mixing the concentrated aroma liquid with the decoction and feeding the mixture to a drier thereby obtaining aroma containing soluble powders.

In yet another aspect of the invention, there is provided a process of aroma enriched soluble powders. The process of producing aroma enriched soluble powders comprises obtaining an extract comprising aroma constituting components. The process further comprises processing the extract to obtain wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components and the wet aroma vapours comprise aroma constituting components and moisture. The process further comprises condensing the wet aroma vapours to obtain a first liquid stream, the first liquid stream comprising aroma constituting components and water. The process further comprises bringing the first liquid stream in contact with a bed comprising zeolite so as to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce the dry aroma vapours. The process further comprises subjecting the dry aroma vapours to condensation to obtain concentrated aroma liquid. The process further comprises concentrating the mother liquor to obtain a decoction. The process further comprises drying the decoction in a drier to obtain partially dried powders. The process further comprises simultaneously drying the partially dried powders and dosing the concentrated aroma liquid thereupon to obtain aroma enriched soluble powders.

In still another aspect of the invention, there is provided a system for producing dry aroma vapours from wet aroma vapours by removing moisture contained in the wet aroma vapours. The system comprises a condensation unit adapted to condense the wet aroma vapours to produce a first liquid stream comprising aroma constituting components and water. The system further comprises a zeolite bed adapted to receive the first liquid stream, the zeolite bed being further configured to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce the dry aroma vapours. In an embodiment of the invention, the system may comprise a temperature control means for controlling a temperature of the zeolite bed such that selective vaporization of the aroma constituting components occurs and vaporization of water does not occur.

In a further aspect of the invention, there is provided a system for producing aroma containing soluble powders. The system comprises an extraction unit adapted to produce an extract comprising aroma constituting components. The system further comprises a separation unit adapted to receive the extract and separate the same into wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components while the wet aroma vapours comprises aroma constituting components and moisture. The system further comprises a first condensation unit adapted to condense the wet aroma vapours to produce a first liquid stream comprising aroma constituting components and water. The system further comprises a zeolite bed adapted to receive the first liquid stream, the zeolite bed being further configured to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce dry aroma vapours. The system further comprises a second condensation unit adapted to receive the dry aroma vapours and condense the same to produce concentrated aroma liquid. The system further comprises a concentration unit adapted to receive the mother liquor and concentrate the same to produce a decoction. The system further comprises a mixing unit adapted to mix the concentrated aroma liquid with the decoction to obtain a mixture. The system further comprises a drier adapted to receive the mixture and produce aroma containing soluble powders there from.

In a furthermore aspect of the invention, there is provided a system for producing aroma enriched soluble powders. The system comprises an extraction unit adapted to produce an extract comprising aroma constituting components. The system further comprises a separation unit adapted to receive the extract and separate the same into wet aroma vapours and mother liquor, wherein the mother liquor is substantially devoid of aroma constituting components while the wet aroma vapours comprises aroma constituting components and moisture. The system further comprises a first condensation unit adapted to condense the wet aroma vapours to produce a first liquid stream comprising aroma constituting components and water. The system further comprises a zeolite bed adapted to receive the first liquid stream, the zeolite bed being further configured to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce dry aroma vapours. The system further comprises a second condensation unit adapted to receive the dry aroma vapours and condense the same to produce concentrated aroma liquid. The system further comprises a concentration unit adapted to receive the mother liquor and concentrate the same to produce a decoction. The system further comprises a drier adapted to receive the decoction and produce partially dried powders there from. The system further comprises a drying and dosing unit adapted to simultaneously dry the partially dried powders and dose the concentrated aroma liquid thereupon to obtain aroma enriched soluble powders. To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRTF.F DESCRIPTION OF THF. DRAWINGS:

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 demonstrates a flow chart of a process for producing dry aroma vapours from wet aroma vapours in accordance with an embodiment of the invention;

Figure 2 demonstrates a block diagram of a system for producing dry aroma vapours from wet aroma vapours in accordance with an embodiment of the invention;

Figure 3 demonstrates a flow chart of a process for producing aroma containing soluble powders in accordance with an embodiment of the invention;

Figure 4 demonstrates a block diagram of a system for producing aroma containing soluble powders in accordance with an embodiment of the invention;

Figure 5 demonstrates a flow chart of a process for producing aroma enriched soluble powders in accordance with an embodiment of the invention; and

Figure 6 demonstrates a block diagram of a system for producing aroma enriched soluble powders in accordance with an embodiment of the invention.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein. hKTLII M) DESCRIPTION OF THI INVENTION:

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises... a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting. Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Referring to Figure 1, there is illustrated a flow chart of a process (100) for producing dry aroma vapours from wet aroma vapours in accordance with an embodiment of the invention. The process (100) comprises condensing (102) the wet aroma vapours to obtain a first liquid stream, the first liquid stream comprising aroma constituting components and water. The process (100) further comprises bringing (104) the first liquid stream in contact with a bed comprising zeolite so as to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce the dry aroma vapours.

It is generally known that zeolite can be of different types and each type can have different pore sizes. Thus, in an embodiment of the invention, the zeolite is selected such that it entraps water molecules in its pores. In an embodiment of the invention, the zeolite is preferably type A zeolite. In a preferred embodiment of the invention, the zeolite is type A zeolite having mean pore diameter equal to or less than 0.5 nm. In a preferred embodiment of the invention, the zeolite is type A zeolite having mean pore diameter of about 0.3 nm.

According to an aspect of the invention, when the first liquid stream comprising aroma constituting elements and water is brought in contact with a bed comprising zeolite, the water is entrapped in the pores of the zeolite while the aroma constituting elements are not entrapped in the pores of the zeolite. Thus, selective entrapment of the water molecule occurs in the zeolite bed or in other words, selective absorption based separation occurs.

Furthermore, when water comes in contact with the zeolite, an exothermic reaction occurs and heat is generated. In an embodiment of the invention, the step of bringing (104) the first liquid stream in contact with the bed comprising zeolite comprises controlling (106) a temperature of the zeolite bed such that selective vaporization of the aroma constituting components occurs and vaporization of water is avoided. By way of example, a temperature of the zeolite bed is maintained at a value in the range of 65°C to 95°C, in particular in the range of 70°C to 92°C. Thus, a selective phase based separation is also occurring in the zeolite bed. Thus, it can be said that in the zeolite bed, selective absorption based separation (because of selective entrapment of the water in the pores of the zeolite) and selective phase based separation (because of selective vaporization of the aroma constituting elements that were forming part of the first liquid stream) are occurring simultaneously.

Because of a combined effect of selective absorption based separation and selective phase based separation, dry aroma vapours comprising predominantly of aroma constituting elements and which is substantially devoid of moisture is obtained. Also, the loss of aroma constituting elements when the first liquid stream is converted to the dry aroma vapours is substantially low. In none of the prior art, a combined effect of selective absorption based separation and selective phase based separation is being taught.

It was observed that the dry aroma vapours comprised of the following aroma constituting elements: 2-Methylbutyraldehyde, 3-Methylbutyraldehyde, Diaetyl, Methylethyl Ketone, N- Butyraldehyde, Methylfuran, Isobutyraldehyde, Methyl Acetate, Acetone, Ethyl Formate, Propionaldehyde, Carbon Disulfide, Methyl Alcohol, Dimethyl Sulfide, C4-C7 Paraffins and Olefins, Methylformate, Furan, Pentadiene (Isoprene), Acetaldehyde, and Methyl Mercaptan.

Referring to Figure 2, there is illustrated a block diagram of a device (200) for producing dry aroma vapours from wet aroma vapours in accordance with an embodiment of the invention. The device (200) comprises a condensation unit (202) adapted to condense the wet aroma vapours to produce a first liquid stream comprising aroma constituting components and water; and a zeolite bed (204) adapted to receive the first liquid stream, the zeolite bed being further configured to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting components to thereby produce the dry aroma vapours.

In an embodiment of the invention, the condensation may occur in a condenser known and reported in the literature. In an embodiment of the invention, the first condensation unit may be a cryogenic condensation unit. In an embodiment of the invention, the zeolite bed (204) is in the form of a fixed zeolite bed reactor (204).

In an embodiment of the invention, the temperature of the zeolite bed can be controlled so as to result in vaporization of only the aroma constituting elements (and not the entrapped water or water present in the first liquid stream). The temperature of the zeolite bed may be controlled in many ways. For example, the zeolite bed (204) is provided with a temperature control means (206) for controlling a temperature of the zeolite bed such that selective vaporization of the aroma constituting components occurs and vaporization of water does not occur. In yet another example, by controlling the rate of reaction between the zeolite and water, the heat generated in the zeolite bed and thus, the temperature of the zeolite bed can be controlled.

In an embodiment of the invention, the temperature control means (206) may be a cooling means for controlling a temperature of the zeolite bed. In an embodiment of the invention, the cooling means may be in the form of a means for introducing cooling air. In yet another alternative embodiment, the cooling means may be in the form of heat exchanger(s) provided in the fixed bed. By way of example, tubes (optionally provided with fins) may be provided in the fixed bed and these tubes (or fins) may be adapted to carry a cooling fluid such as water, cold air, cold oil, etc. thereby effect cooling of the zeolite bed. In yet another alternative embodiment, cooling jacket(s) may be provided to cool the zeolite bed. In yet another alternative embodiment, cooling thermostats may be incorporated in the zeolite bed so that the temperature of the bed could be controlled. Any other conventional mechanism for cooling the zeolite bed may be incorporated in the zeolite bed so that the temperature of the bed could be controlled (to maintain the temperature of the bed at a desired level as stated above).

In an embodiment of the invention, the rate of reaction between the zeolite and water can be controlled by controlling the rate of flow of the first liquid stream through the zeolite bed. The rate of flow of the first liquid stream through the zeolite bed can be controlled using valves (208) which feed the first liquid stream to the zeolite bed.

Since the zeolite bed absorbs water, at some point of time, the process has to be interrupted for purging the water absorbed and for regenerating the zeolite bed (204).

Thus, in an embodiment of the invention, plurality of zeolite beds (2041, 204 ₂ , 204 ₃ , ...) may be provided so that un-intermpted operation may be carried out. For example, three fixed bed reactors (204i, 204 ₂ , 204 ₃ ) may be provided such that in the first fixed bed reactor (204i) the first liquid stream is brought in contact with the zeolite bed to produce dry aroma vapours, in the second fixed bed reactor (204 ₂ ) the water entrapped in the zeolite bed is purged (or removed) and, the third fixed bed reactor (204 ₃ ) is cooled and brought to the appropriate operating condition (i.e. regenerated). The first, the second, and the third fixed bed reactors can be operating in cyclic manner to so that un-interrupted operation may be carried out.

Although not illustrated, in an alternative embodiment, two fixed bed reactors can be operating in cyclic manner so that un-interrupted operation may be carried out. For example, the first liquid stream may be brought in contact with the zeolite bed in the first fixed bed reactor to produce the dry aroma vapours, while purging and regeneration may be performed in the second fixed bed reactor.

Depending upon the configuration of the system i.e. whether the device is of two fixed bed reactor configuration or of three fixed bed reactor configuration, flow controlling valve(s) (208) may be provided.

In an embodiment of the invention, the fixed bed reactor (204i, 204 ₂ , 204 ₃ ) is provided with a purging means (210) for purging the water entrapped in the zeolite bed. In an embodiment of the invention, the purging means (210) can be in the form of a means for introducing hot air into the zeolite bed for purging the water entrapped therein. The hot air that may be introduced into the fixed bed reactor may by way of example, have a temperature in excess of 100°C. In an alternative embodiment, the purging means (210) can be in the form of a means for introducing an inert air such as nitrogen into the fixed bed reactor for the purposes of purging the water entrapped in the zeolite bed. In yet another alternative embodiment, the purging means (210) may be in the form of at least one tube provided in the zeolite bed, the at least one tube being adapted to carry a hot fluid such as steam, hot air, hot oil etc. to purge the water from the zeolite bed. In yet another alternative embodiment, the purging means (210) may be in the form of at least one heating element, such as an electrical filament, provided in the zeolite bed. The at least one heating element is adapted to be heated and thereby purge water from the zeolite bed.

After purging, the temperature of the zeolite bed may be high (for example, in excess of 100°C) and may result in vaporization of water as well as the aroma constituting elements. Thus, in an embodiment of the invention, the temperature of the zeolite bed is brought to a value in the range of 65°C to 95°C, in particular in the range of 70°C to 92°C. The temperature of the zeolite bed can be reduced using the temperature control means (206). This is referred to as regeneration of the zeolite bed (204). Now referring to Figure 3, there is illustrated a process (300) for producing aroma containing soluble powders. The process (300) comprises obtaining (302) an extract comprising aroma constituting elements. The process (300) further comprises processing (304) the extract so as to obtain mother liquor substantially devoid of aroma constituting elements and wet aroma vapours comprising aroma constituting elements and moisture. The process (300) further comprises producing dry aroma vapours from the wet aroma vapours in accordance with the process as described above (for example, as described above with reference to Figure 1). In particular, the wet aroma vapours is subjected to condensation (306) to obtain a first liquid stream comprising aroma constituting elements and water and the first liquid stream is brought (308) in contact with a zeolite bed so as to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting elements so as to produce a dry aroma vapours.

The process (300) further comprises subjecting the dry aroma vapours to condensation (310) to obtain concentrated aroma liquid. The process (300) further comprises concentrating (312) the mother liquor to obtain a decoction. The process (300) further comprises mixing (314) the concentrated aroma liquid with the decoction to obtain a mixture. The process (300) further comprises drying (316) the mixture thus obtained thereby obtaining aroma containing soluble powders.

In an embodiment of the invention, the step of obtaining (302) an extract comprising aroma constituting elements comprises extracting a solid material selected from a group comprising of roasted coffee bean powders, tea leaves, and fruits with a solvent. In an embodiment of the invention, the extraction process (302) may be a high pressure extraction process or a low pressure extraction process or a co-current extraction process or a counter current extraction process. In an embodiment of the invention, the extraction process (302) may preferably be a continuous counter current extraction process, wherein hot de-mineralized water may be used as the solvent.

In an embodiment of the invention, the step of processing (304) the extract comprises at least one of steam stripping process, stripping with inert gas, flashing, collecting gases evolved during the extraction process, and heating in a rotary cone column. In an embodiment of the invention, processing (304) the extract may preferably be a carried out in a rotary cone column. As the step of producing dry aroma vapours from the wet aroma vapours (which in turn comprises the steps of subjecting the first liquid stream to condensation (306) to obtain the first liquid stream and bringing (308) the first liquid stream in contact with a zeolite bed) has been described in detail with reference to Figure 1, for further details of how these steps are performed, reference may be made to the description of Figure 1 as provided above.

In an embodiment of the invention, condensation of the dry aroma vapours to produce concentrated aroma liquid may occur in a condenser known and reported in the literature. In an embodiment of the invention, the condensation step may involve a cryogenic condensation step wherein the temperature of the second volatile stream is brought to a sub-zero value.

In an embodiment of the invention, if a volume of the first liquid stream is compared with a volume of the concentrated aroma liquid, a volume of the concentrated aroma liquid is not more than 20% of a volume of the first liquid stream and hence, a volume reduction to the extent of equal to or greater than 80% is obtained. In a preferred embodiment of the invention the volume of the concentrated aroma liquid is not more than 15% of the volume of the first liquid stream and hence, volume reduction to the extent of equal to or greater than 85% is obtained. In a more preferred embodiment of the invention, the volume of the concentrated aroma liquid is not more than 10% of the volume of the first liquid stream and hence a volume reduction to the extent of equal to or greater than 90% is obtained.

In an embodiment of the invention, the step of concentrating the mother liquor to obtain the decoction may involve an evaporation step. In an embodiment of the invention, the concentration by evaporation of the mother liquor is performed preferably under a vacuum.

In an embodiment of the invention, the concentrated aroma liquid may be mixed with the decoction in a traditional mixing unit to obtain a mixture.

In an embodiment of the invention, the aroma containing soluble powders are obtained by spray drying the mixture that comprises the concentrated aroma liquid and the decoction in a spray drier. In an embodiment of the invention, any other conventionally known mechanism of obtaining dried powders such as spray drying, freeze drying, etc. may be adopted.

Now referring to Figure 4, there is illustrated a block diagram of a system (400) for producing aroma containing soluble powders in accordance with an embodiment of the invention. The system (400) comprises an extraction unit (402) adapted to obtain an extract comprising aroma constituting elements. The system (400) further comprises a separation unit (404) adapted to process the extract to obtain mother liquor substantially devoid of aroma constituting elements and wet aroma vapours comprising of aroma constituting elements and moisture.

In an embodiment of the invention, the system (400) further comprises a device for producing dry aroma vapours from wet aroma vapours (for example, as described above with reference to Figure 2). In particular, the device for producing dry aroma vapours from wet aroma vapours comprises a first condensation unit (406) that receives the wet aroma vapours and condenses the same to obtain a first liquid stream comprising aroma constituting elements and water and a zeolite bed (408) adapted to receive the first liquid stream, selectively entrap water in the pores of the zeolite and selectively vaporization the aroma constituting elements so as to produce a dry aroma vapours. The system (400) further comprises a second condensation unit (410) adapted to condense the dry aroma vapours to obtain concentrated aroma liquid.

In an embodiment of the invention, the system (400) further comprises a concentration unit (412) adapted to receive the mother liquor from the separation unit (404). The concentration unit (412) is further adapted to produce a decoction by concentrating the mother liquor. In an embodiment of the invention, the system (400) further comprises a mixer (414) for mixing the concentrated aroma liquid with the decoction and to produce a mixture. The system (400) further comprises a drying unit (416) adapted to receive the mixture (containing the decoction and the concentrated aroma liquid) and produce aroma containing soluble powders there from.

In a preferred aspect of the invention, the extraction unit (402) may be a counter current extraction unit. In the counter current extraction unit, a solid material (such as roasted coffee bean powders, tea leaves, fruits, as the case may be) is brought in contact with a solvent (such as hot water). The counter current extraction unit produces an extract and spent material. The spent material may be treated as per conventional techniques prior to disposal. It may however be noted that instead of counter current extraction unit any other conventional device such as a high pressure extraction device or a low pressure extraction device or a co current extraction device may be used for producing the extract. In an embodiment of the invention, separation unit (404) may be any of the traditional equipments. In an embodiment of the invention, separation unit (404) may preferably be a rotary cone column.

As the device for producing dry aroma vapours from the wet aroma vapours (which in turn comprises a first condensation unit (406) and the zeolite bed (408)) has been described in detail with reference to Figure 2, the description of Figure 2 as provided above may be referred for understanding further details of this device.

In an embodiment of the invention, the dry aroma vapours is provided to a second condensation unit (410) to obtain a concentrated aroma liquid. In an embodiment of the invention, the second condensation unit (410) may be of a type known and reported in the literature. In an embodiment of the invention, the second condensation unit (410) may be a cryogenic condensation unit.

In an embodiment of the invention, the mother liquor as obtained from the separation unit (404) is guided to a concentration unit (412) so as to reduce the volume of the mother liquor and thereby obtain the decoction. In an embodiment of the invention, the concentration unit (412) may be an evaporation unit. In an embodiment of the invention, the concentration unit may be a vacuum evaporation unit.

The decoction thus obtained from the concentration unit (412) and the concentrated aroma liquid as obtained from the second condensation unit (410) are led to a mixer (414) to obtain a mixture. The mixer (414) may be of a type known and reported in the literature. In an embodiment of the invention, the system (400) comprises a drier (416) to which the mixture obtained from the mixer (414) is fed.

In an embodiment of the invention, the drier (416) may comprise a spray drier (418) defining a top end (420) and a bottom end (422). At about the top end (420), a spraying nozzle (424) is provided. The spraying nozzle is connected to the mixer (414). The spraying nozzle (424) sprays the mixture into the spray drier (418). The drier (416) further comprises an air pump (426) supplying ambient air to a heating element (428). The heating element (428) heats the ambient air to produce a drying air and introduces the same into the spray drier (418) at about the top end (420). The spray drier (418) defines an output port (430) at about a bottom end (422) for withdrawing the spray dried powders thus formed. At about a top end (420), the spray drier (418) is further provided with an exhaust gas withdrawal means (432). The exhaust gas as withdrawn by the exhaust gas withdrawal means (432) is fed to a solid-gas separator (434). The solid as obtained from the solid-gas separator (434) is fed back to the spray drier (418) via a solid feeding mechanism (436) while a gas stream may be vented out. The output port (430) may be coupled to a secondary drier (438). The secondary drier (438) may be adapted to further dry the spray dried powders. It may be noted that providing the secondary drier (438) is optional and not essential. In an embodiment of the invention, the secondary drier (438) may be coupled to a hot air supply unit (440).

Now referring to Figure 5, there is illustrated a flow chart of the process (500) for producing aroma enriched soluble powders in accordance with an embodiment of the invention. The process (500) comprises obtaining (502) an extract comprising aroma constituting elements. The process further comprises processing (504) the extract so as to obtain mother liquor substantially devoid of aroma constituting elements and wet aroma vapours comprising aroma constituting elements and moisture.

In an embodiment of the invention, the process (500) further comprises producing dry aroma vapours from the wet aroma vapours in accordance with the process as described above (for example, as described above with reference to Figure 1). In an embodiment of the invention, the process (500) comprises condensing (506) the wet aroma vapours to obtain a first liquid stream comprising aroma constituting elements and water. The process (500) further comprises bringing (508) the first liquid stream in contact with a zeolite bed so as to selectively entrap the water in the pores of the zeolite and selectively vaporize the aroma constituting elements thereby producing dry aroma vapours comprising predominantly of aroma constituting elements.

The process (500) further comprises subjecting the dry aroma vapours to condensation (510) to obtain concentrated aroma liquid comprising predominantly of aroma constituting elements. In an embodiment of the invention, the process (500) further comprises concentrating (512) the mother liquor (as obtained in step (504)) to obtain a decoction.

In an embodiment of the invention, the process (500) further comprises drying (514) the decoction in a spray drier to obtain partially dried powders. The process further comprises simultaneously (516) drying the partially dried powders and dosing the concentrated aroma liquid thereupon to obtain aroma enriched soluble powders. In an embodiment of the invention, the step of obtaining (502) an extract comprising aroma constituting elements comprises extracting a solid material (such as roasted coffee bean powders, tea leaves, fruits, as the case may be) with a solvent. In an embodiment of the invention, the extraction process (502) may be a high pressure extraction process or a low pressure extraction process or a co-current extraction process or a counter current extraction process. In an embodiment of the invention, the extraction process (502) may preferably be a continuous counter current extraction process, wherein hot de-mineralized water may be used as the solvent.

In an embodiment of the invention, the extract is processed so as to obtain mother liquor substantially devoid of aroma constituting elements and wet aroma vapours comprising aroma constituting elements and moisture. Thus, it can be said that the aroma constituting elements as present in the extract are separated from the extract. In an embodiment of the invention, processing (504) the extract so as to obtain mother liquor substantially devoid of aroma constituting elements and the wet aroma vapours may be any of the traditional processes including but not limited to steam stripping process, stripping with inert gas, flashing, collecting gases evolved during the extraction process, heating in a rotary cone column, etc. In an embodiment of the invention, processing (504) the extract may preferably be a carried out in a rotary cone column.

As the step of producing dry aroma vapours from the wet aroma vapours (which in turn comprises the steps of subjecting the first liquid stream to condensation (506) to obtain the first liquid stream and bringing (508) the first liquid stream in contact with a zeolite bed) has been described in detail with reference to Figure 1, for further details of how these steps are performed, reference may be made to the description of Figure 1 as provided above.

In an embodiment of the invention, the dry aroma vapours comprising predominantly of aroma constituting elements and which is substantially devoid of moisture thus obtained is subjected to a condensation step (510) so as to obtain concentrated aroma liquid comprising the aroma constituting elements. In an embodiment of the invention, the condensation may occur in a condenser known and reported in the literature. In an embodiment of the invention, the condensation step may involve a cryogenic condensation step wherein the temperature of the second volatile stream is brought to a sub-zero value. In an embodiment of the invention, if a volume of the first liquid stream is compared with a volume of the concentrated aroma liquid, a volume of the concentrated aroma liquid is not more than 20% of a volume of the first liquid stream and hence, a volume reduction to the extent of equal to or greater than 80% is obtained. In a preferred embodiment of the invention the volume of the concentrated aroma liquid is not more than 15% of the volume of the first liquid stream and hence, volume reduction to the extent of equal to or greater than 85% is obtained. In a more preferred embodiment of the invention, the volume of the concentrated aroma liquid is not more than 10% of the volume of the first liquid stream and hence a volume reduction to the extent of equal to or greater than 90% is obtained.

In an embodiment of the invention, the mother liquor substantially devoid of aroma constituting elements as obtained (in step (504)) is subjected to a concentration step (512) so as to reduce the volume of the mother liquor and thereby obtain the decoction. In an embodiment of the invention, the concentration step may involve an evaporation step. In an embodiment of the invention, the concentration by evaporation of the mother liquor is performed preferably under a vacuum.

The decoction thus obtained is dried (514) in a dryer to obtain partially dried powders. In an embodiment of the invention, any other conventionally known mechanism of obtaining partially dried powders such as spray drying, freeze drying, etc. may be adopted. It may be noted that partially dried powders thus obtained contains no or very little aroma.

In an embodiment of the invention, once the partially dried powders have been formed, it is simultaneously subjected to drying and aroma dosing (516) to obtain aroma enriched soluble powders. The aroma dosing is performed using the concentrated aroma liquid thus obtained.

Now referring to Figure 6, there is illustrated a block diagram of a system (600) for producing aroma enriched soluble powders in accordance with an embodiment of the invention. The system (600) comprises an extraction unit (602) adapted to obtain an extract comprising aroma constituting elements. The system (600) further comprises a separation unit (604) adapted to process the extract to obtain mother liquor substantially devoid of aroma constituting elements and wet aroma vapours comprising of aroma constituting elements and moisture. In an embodiment of the invention, the system (600) further comprises a device for producing dry aroma vapours from wet aroma vapours (for example, as described above with reference to Figure 2). In particular, the device for producing dry aroma vapours from wet aroma vapours comprises a first condensation unit (606) that receives the wet aroma vapours and condenses the same to obtain a first liquid stream comprising aroma constituting elements and water; and a zeolite bed (608) adapted to receive the first liquid stream, selectively remove water from the first liquid stream and to produce dry aroma vapours comprising predominantly of aroma constituting elements.

In an embodiment of the invention, the system (600) further comprises a second condensation unit (610) adapted to condense the dry aroma vapours to obtain concentrated aroma liquid. In an embodiment of the invention, the system (600) further comprises a concentration unit (612) adapted to receive the mother liquor from the separation unit (604). The concentration unit is further adapted to produce a decoction by concentrating the mother liquor.

In an embodiment of the invention, the system (600) further comprises a drying unit (614) adapted to receive the decoction and produce partially dried powders there from. The system (600) further comprises a drying and dosing unit (616) adapted to simultaneously dry the partially dried powders and dose the concentrated aroma liquid thereupon to obtain aroma enriched soluble powders.

In an embodiment of the invention, the drying unit (614) comprises a spray drier (618) defining a top end (620) and a bottom end (622). At about the top end (620), a decoction spraying nozzle (624) is provided. The decoction spraying nozzle (624) is connected to the concentration unit (612) for receiving decoction there from. The drying unit (614) further comprises an air pump (626) supplying ambient air to a heating element (628). The heating element (628) heats the ambient air to produce a drying air and introduces the same into the spray drier (618) at about the top end (620). The spray drier (618) defines an output port (630) at about a bottom end (622) for withdrawing the partially dried powders thus formed. At about a top end (620), the spray drier (618) is further provided with an exhaust gas withdrawal means (632). The exhaust gas as withdrawn by the exhaust gas withdrawal means (632) is fed to a solid-gas separator (634). The solid as obtained from the solid-gas separator (634) is fed back to the spray drier (618) via a solid feeding mechanism (636) while a gas stream may be vented out. In an embodiment of the invention, the drying and dosing unit (616) forms part of a secondary drier (638) which is operatively coupled to the output port (630) of the spray drier (618). In an embodiment of the invention the secondary drier (638) may be coupled to a hot air supply unit (640). Within the secondary drier (638), hot air is introduced so as to dry the partially dried powders thus received from the output port (630) of the spray drier. Within the secondary drier and at a location which is downstream compared to a location of introduction of the hot air, a micro-dosing unit (not specifically illustrated) is provided. The micro-dosing unit sprays the concentrated aroma liquid on to the soluble powders which has been dried using the hot air in the secondary drier (638). Thus, subsequent to spraying of the concentrated aroma liquid, which leads to production of aroma enriched soluble powders, the aroma enriched soluble powders is not subjected to heating.

Comparing the process of the present invention with the prior art techniques it can be observed that in the prior art processes, wet coffee aroma gas comprising moisture is brought in contact with the bed comprising zeolite. On the other hand, in the process of the present invention, the wet aroma vapours is first converted into the first liquid stream comprising the aroma constituting elements and water and thereafter the first liquid stream is brought in contact with the zeolite bed. Thus, the dry aroma vapours which is substantially devoid of moisture is obtained because of a combined effect of selective absorption based separation and selective phase-change based separation, which is not adopted in any of the reported prior art processes.

Applicant believes that the aforesaid difference leads to one or more of the following advantages:

(a) a quality of concentrated aroma liquid obtained is high and hence, the process becomes more economical;

(b) an amount of moisture present in the concentrated aroma liquid is negligible or very less;

(c) loss of the aroma constituting elements in the concentrated aroma liquid is negligible or very less the and hence, the consumer perception is not adversely affected;

(d) the morphology of the dried powders as produced by the process as described with reference to Figure 5 is not adversely affected (compared to the dried powders as produced by the process as described with reference to Figure 3);

(e) an amount of aroma constituents incorporated in the dried powders increases substantially. While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the present disclosure. Indeed, the novel methods, devices, and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the methods, devices, and systems described herein may be made without departing from the spirit of the present disclosure.