Note: Descriptions are shown in the official language in which they were submitted.
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
1
DISTRIBUTION METHODS FOR DISTRIBUTING AND DISPENSING
BEVERAGES AND LIQUID FOOD PRODUCTS
This invention relates to methods for distributing and dispensing beverages
and liquid food products.
Bottled water distribution is one of the most important markets in the food
industry, with a value in the billions of US dollars.
Currently, bottled drinking water is distributed to customers using large
polycarbonate bottles. Such bottles traditionally hold 15-19 litres of product
and,
correspondingly, weigh between 15-19 kg. These bottles are recycled but the
hygiene practices necessary to provide some measure of integrity pose an
ongoing problem for the industry.
Hygiene is a major consideration. Maintaining the HACCP (Hazard and
Critical Control Points) system when a bottle has been used by a consumer,
returned without a cap and subsequently stored by a retailer prior to washing
and
sterilising the bottles is difficult. It is difficult to monitor whether the
bottle has
been put to storage of toxic substances or substances incompatible with the
safe
distribution of bottled water. Contamination is a difficult problem to detect
prior to
consumption. Taint/discolouring or chemical after taste of water are familiar
problems.
Second, usage of the large polycarbonate bottles pose risk of injury to
personnel distributing the bottles or customers of drinking water supplied in
the
bottles. If the bottles fall, they may cause significant injury. This raises a
significant occupational health and safety issue.
Third, storage, transportation and recovery of bottles creates significant
expense. If bottles are trucked to distribution points and customers, by
larger
trucks, as is usual practice, the biggest cost issue is the Cubic Metre rate
charged
for empty or full cages with wasted area due to the round bottles. Rising fuel
prices do not assist. Such trucks may also require a lifting device to cope
with the
heavy bottles. Usage of caged trucks may also create exposure to dust/oil etc
and other forms of airborne contaminants whilst the bottles are on the tray of
the
truck. This may lead to product of unhygienic quality. There is thus an
overlap
between the contamination problems discussed above and the transport
economics issue.
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
2
Fourth, polycarbonate or like bottles are typically provided with a plastic
seal or cap that the customer or operator must remove prior to placing the
bottle
in a dispenser. Spillage and wastage of drinking water may result as a bottle
is
inverted and placed into a dispensing position in the dispenser. Insects,
airborne
bacteria and dust may also pollute the water at this point making it
unhygienic.
It is an object of the present invention to provide methods and devices for
distributing and dispensing beverages, such as drinking water, to customers
that
address the above described health, safety and cost issues with prior art
distribution methods and devices.
With this object in view, the present invention provides a method of
distributing flexible bags filled with beverage or liquid food product under
sterile
conditions, preferably through a spout or tap forming part of each flexible
bag, to
a consumer of said beverage or liquid food product in return for payment and
comprising the following steps of distribution:
a) locating said flexible bags filled with beverage or liquid food product
in a bulk transport container having capacity for a plurality of flexible
bags;
b) transportation, by a commercial distributor, of the bulk transport
container in which the filled flexible bags are located to a consumer of said
beverage or liquid food product; and
c) unloading a required quantity of flexible bags for delivery to the
consumer; and
d) delivering each flexible bag for dispensing the beverage or liquid
food product contained in the flexible bag to be consumed by an end consumer,
wherein, through each step, hazard and critical control points during
distribution
of beverage and liquid food products are minimised.
Such hazards associated with beverage or food include physical hazards,
such as of impact injury, or chemical or biological hazards such as posed by
toxins, microbes or other contaminants. Critical control points are points in
the
distribution system where such potential hazards can be minimised or avoided.
The commercial distributor may, itself, fill the flexible bags with drinking
water, other beverages, such as fruit juices, milk and so on or other liquid
food
products using an automated filling or packaging line under sterile
conditions.
Such liquids may have comparable density and/or viscosity to water. It is not
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
3
intended that the flexible bags be re-used. The distribution method may be
"one
way". There is no requirement for the flexible bags to be recovered for re-
use,
thus incurring the hazards of contamination which are difficult to detect and
which
erode the integrity of the HACCP chain as described above. That is, the
distributor "disposes", in a property sense, of the flexible bags. Storage
costs and
recovery costs may also be avoided. However, a customer can use a recycle or
disposal service so that the material of the flexible bag can be re-used or
responsibility disposed of.
Flexible bags are desirably filled through a tap, outlet, spout, valve or
other
dispenser forming part of the bag rather than through a form, fill and seal
method
which is a way of beneficially avoiding a critical control point being a
residue from
that sealing process. In addition, such a bag is sealed in the manufacturing
process and not in the filling process. Thus, a better quality seal is
achieved.
Special polymer sealing devices may also be avoided, saving cost. The tap may
be fitted to the bag after manufacture. Any form of flexible bag, preferably
of
simple, hygienic and inexpensive construction, can otherwise be used.
The commercial distributor may also mount, for example by positioning, the
flexible bags in a dispenser for dispensing the drinking water, other beverage
or
liquid food product. The distributor may supply dispensers to customers on a
rental, sale or other basis as part of the distribution service. The
distributor may
service the dispensers in accordance with a maintenance schedule. The
dispenser, when a refrigerated cooler, is equipped with cooling means.
Drinking
water is typically chilled prior to customer consumption so a dispenser for
drinking
water would usually incorporate a chilling unit.
The bulk transport container used for transportation of the flexible bags is
intended to accommodate a plurality of flexible bags while advantageously
being
adaptive to varying quantities of these bags in accordance with consumer
demand. In other words, the bulk transport container is, advantageously, of
variable capacity and/or collapsible. Packaging or "boxing" of individual
flexible
bags is avoided. In this way, easier and less expensive inventory management
may be achieved with economics not requiring that a large minimum quantity of
product, as necessary with polycarbonate bottled water distribution systems,
be
accepted by a distributor or sub-distributor.
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
4
A suitable bulk transport container is a bulk transport container of cubic or
analogous design having smooth wall and base construction with provision for a
side-gate for readier access. The construction of the container reduces risk
of
damage to, and contamination of, the flexible bags during transportation or
storage (critical control points). The container may be made of polymer, such
as
High Density Polypropylene, (HDPP) suitable for use in food grade
environments.
Such a container may be collapsible to achieve variable capacity. The return
ratio of the bulk transport container may be selected to achieve efficient use
of
storage space and enable economic use of transport vehicles without wastage of
space on the vehicle. The containers are stackable.
The flexible bags may be filled in a central location and then distributed to
distribution centres prior to distribution to multiple customers in multiple
locations.
Direct distribution from the central location is an alternative. A central
distributor
may, in a franchising system, authorise franchisees or others to distribute
beverages and/liquid food products in accordance with the method of the
invention. Capacity of the bulk transport container is varied in accordance
with
the volume of beverage or liquid food product to be delivered. The bulk
transport
container may be employed in collapsed state for smaller volumes and flexible
bag inventory. Supervision of deliveries, inventory and payment may be
conducted using a computer system.
The flexible bags may incorporate at least one handle. The handle(s)
allow easier lifting and may accommodate support means to position or hold the
flexible bag in a dispenser allowing substantially complete drainage of the
liquid
contents from the flexible bag to minimise wastage. The handle may crimp a
flexible bag within a grip of the handle. The handles may allow positioning or
holding of the flexible bag within the dispensers. The flexible bags may be
cylindrical in shape when filled or may adopt a cylindrical shape when placed
within the dispenser. The bags may accommodate any desired volume such as a
volume of less than 15 litres, preferably between 10 to 15 litres, of product,
the
aim being to reduce hazard if the bags are dropped during transport.
Dispensers suitable for holding flexible bags may comprise a housing to
locate the flexible bags during dispensing of the beverage or liquid food
product
and minimise contamination. The housing may include a support means, which
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
may co-operate with handles(s) forming part of the flexible bag, to support
the
flexible bag within the housing. A cylindrical housing or a housing with a
cylindrical inner surface may accommodate flexible bags that adopt the shape
of
a cylinder when inserted into the housing. Seams of the flexible bags may be
5 arranged such that a cylindrical shape is formed on filling of the flexible
bags. A
base of the housing may be angled, or otherwise configured, with respect to a
vertical axis of the housing to allow substantially complete drainage of the
contents of the flexible bag from the dispenser under gravity to a tap or
other
delivery means for water or liquid food product to a consumer. The base could
be
formed with a contour or funnel shape. A housing may be of flared construction
to facilitate positioning of a flexible bag within the dispenser. A
positioning or
hanging arrangement for a flexible bag may be avoided in this manner though it
may be adopted if desired. The chilling unit may be arranged to chill the base
of
the housing of the dispenser.
The flexible bag may be provided with, or communicated with, an outlet
spout tap or valve which may co-operate with other delivery means forming part
of the dispenser to deliver the beverage or liquid food product for
consumption by
the customer. The tap may be accommodated within a slot or bore formed within
the housing of the dispenser. The tap is fed by gravity. Pumped systems, in
which liquid product requires to be pumped from the flexible bag are desirably
and advantageously avoided. A shield, for example of polymeric or composite
material, may be disposed between the flexible bag and the inner wall of the
housing of the dispenser to protect the lower portion of the flexible bag and
tap
from damage. The shield may be located proximate the tap, valve or spout of
the
bag and/or slot or bore in the housing of the dispenser.
Commercial distributors may conduct any or each of the steps of the
method as a single entity, a vertically integrated entity and/or through one
or more
parties selected from the group of their contractors, servants or agents.
Consumers may be domestic, industrial or commercial consumers.
"Consumers" may be bailees of the filled flexible bags on behalf of others.
That
is, "consumers" as used herein may encompass owners and operators of storage
facilities for storage of the filled bags on behalf of the commercial
distributor. The
"end consumer" is an individual or group of individuals which actually
consumes
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
6
the beverage. A consumer may also comprise a community to which water or
other beverages and liquid food products require to be supplied for health,
hygiene or supply restriction reasons caused by war or natural disaster. Such
communities may be remotely located from major population centres.
The invention may be more fully understood from the following description
of preferred embodiments thereof made with reference to the drawings in which:
Figure 1 a is a side view of an unfilled flexible bag used in accordance with
a preferred embodiment of the distribution method of the invention;
Figure 1 b is a perspective view of the tap fitted to the flexible bag of
Figure
1a;
Figure 1 c is a front view of a handle for the flexible bag of Figure 1 a;
Figure 1 d is a top view of the handle of Figure 1 c;
Figure 2 is a perspective view of a transport vehicle loaded with bulk
transport containers loaded with filled flexible bags in accordance with a
preferred
embodiment of the distribution method of the invention;
Figure 3 is a perspective section view of a bulk transport container filled
with flexible bags for distribution in accordance with a preferred embodiment
of
the distribution method of the invention;
Figure 4 is a perspective view of the bulk transport container of Figure 3 in
collapsed condition with approximately one third of maximum capacity;
Figure 5 is a perspective view of the bulk transport container of Figure 4 in
expanded condition or full capacity as used in accordance with a preferred
embodiment of the distribution method of the invention;
Figure 6 is a perspective view of a dispenser, being a refrigerated cooler,
loaded with a filled flexible bag in accordance with a further aspect of the
present
invention;
Figure 7 is a perspective view of a dispenser, being a refrigerated cooler,
suitable for bench top application;
Figure 8 is a perspective view of the housing of a dispenser suitable for
use in accordance with a preferred embodiment of the distribution method of
the
present invention;
Figure 9a is a top view of the housing of Figure 8; and
Figure 9b is a front view of the housing of Figure 8;
CA 02582443 2011-07-21
7
Figure 9c is a side view of the housing of Figure 8' and
Figure 10 is a front view of a shield to protect a tap of a dispenser used in
accordance with a preferred embodiment of the distribution method of the
present
invention.
In accordance with the distribution method of the invention, a distributor of
a beverage or liquid food product procures flexible bags 10, of the form shown
in
Figure 1 a,. Such bags 10 are of polymeric construction suitable for food
grade
applications, and designed to withstand ordinary handling which could involve
wear. Such flexible bags 10 are fitted at tap hole 12 or formed with a valve,
spout
or tap through which a beverage, for example, drinking water, is directed to
fill the
bag. A suitable tap 20 is described in US Patent Nos 6296157 and 6360925, in
the name of Scholle Corporation.
Such a tap 20 is shown in perspective in Figure 1b. It has an
actuator 21 to actuate flow of liquid and a ribbed end 22 to allow socket
fitting into
tap hole 12, the ribs forming the seal with a smooth internal bore of the tap
hole
12. Avoidance of threading of end 22 avoids potential risk of abrasion and
flow of
debris into the liquid product and contaminating it. The flexible bag 10 is of
rectangular shape, when flat, and is provided with a pocket 14 disposed
between
seams 11 of the bag 10. Transverse seams 11 and 17 and longitudinal seams 19
are formed in the bag 10. A handle 15, as shown in detail in Figures 1c and 1
d,
may be fitted through the pocket 14 to support the bag 10 in a dispenser or to
facilitate carriage by distributor or consumer. The illustrated handle 15 is
of
polyethylene or propylene formed in a loop. Rod portion 15b may be inserted
through pocket 14 of bag 10 and secured by fitting sleeve 15c over a barb
portion
15a of rod portion 15b. Loop 15d allows the handle 15 to be positioned or hung
in a dispenser, as shown in Figure 6, for example by a locator. The volume of
a
single bag is about 11 litres filled and weighs less than 12 kg (density of
water 1.0
g/cc at ambient conditions) though bags of flexible or different volume may be
catered for. Seams 16 and 17 are arranged such that, when placed in a
dispenser, a "funnel" or contour will be formed at the base of bag 10 to
facilitate
drainage of liquid product to the base under gravity. The diagonal disposition
of
seams 16 illustrate how the funnel is formed. This minimises wastage of liquid
product.
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
8
The distributor of drinking water uses a conventional automated packaging
or filling line, to fill flexible bags 10, under sterile conditions as
dictated by
applicable health or quality standards, with drinking water. Other beverages
or
liquid food products are alternative product options. Drinking water
applications
are described from here on by way of advantageous example. A large number of
flexible bags 10 may be filled continuously over a period of time. The
packaging
line may be operated continuously or intermittently and may be arranged to
deliver different liquid products, that is, water, orange juice and so on
during a
filling run. Flexible bags 10 do not require individual packaging in
containers such
as boxes or other bags as familiar in the "bag in box" art. Indeed, this is
very
desirably avoided with cost savings. Arrangement of seams 11,. 17 and 19 may
enable the flexible bag 10 to adopt a cylindrical shape on filling.
Filled flexible bags 10 are located within a bulk transport container 30 as
shown in Figures 2 to 5. No specific mounting is required using hangers,
straps
or the like. The bags 10 are neatly stacked in the container. Such a bulk
container 30 is available under the trade mark GEM.CON from Chep
International. Such a container 30 has smooth wall and base construction with
provision for a side-gate for readier access. Slots 32 in the wall allow
lifting by
forklift truck as necessary. Lid 31 is detachable and may be tamper proof. The
container may be made of polymer, such as High Density Polypropylene (HDPP),
suitable for use in food grade environments. The construction of bulk
transport
container 30 helps protect flexible bags 10 from damage or contamination
during
transportation. Such a container 30 is collapsible with return ratio selected
to
achieve efficient use of storage space and enable economic use of transport
vehicles without wastage of space on/in the vehicle. Container 30 has an about
3:1 return ratio allowing its volume to be reduced by up to two thirds, as
necessary, and as illustrated by comparison of Figures 4 and 5 enabling more
efficient use of storage space during warehousing and transportation. This may
be achieved by folding of the walls of container 30 to the most appropriate
capacity for the number of flexible bags 10 of liquid food product or beverage
to
be delivered. The detachable lid 31 is then placed into position. Flexibility
in
selection of transport vehicle to save transport costs is also achieved by
ability to
vary capacity of container 30.
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
9
A single bulk transport container 30 may accommodate 60-65 of the 11
Litre volume flexible bags. Container 30 helps to isolate bags 10 from dust
and
oil contamination. Such bulk transport containers 30 may then be placed in a
vehicle of suitable selected storage capacity including a land transport
vehicle,
water transport vehicle or aircraft for transportation of the container and
drinking
water to any desired location. Figure 2 shows a flat top truck 50 loaded with
a
number of bulk transport containers 30 stacked in two layers for a large bulk
delivery. Such location may be a remote location affected by war, disaster or
shortage of drinking water.
A commercial distributor, being a supplier of drinking water to customers of
residential, industrial or commercial kind, may transport the bulk transport
containers 30 directly to, or may supervise the transportation to, customers
and
consumers. While the distributor may transport drinking water directly to a
consumer, for example from a central location, the distributor may supply to
sub-
distributors or franchisees of a beverage supplier for distribution to
consumers.
Bulk transport containers 30 may have variable capacity adaptive to various
delivery sizes. Such franchisees, included within the definition of
"commercial
distributor" used in this specification, may be supplied from a central
location and
transport economics may allow smaller quantities of beverage (drinking water)
to
be economically supplied to customers than is possible with a bottled water
distribution system where bottle storage space may create lack of economy.
Avoidance of bottles also limits safety issues for personnel lifting bottles.
Flexible
bags are less likely to cause injury than rigid bottles having less weight and
impact.
The distributor or franchisee may assist the customer by mounting a filled
flexible bag 10 containing beverage within a dispenser 40 being a refrigerated
cooler. A suitable dispenser will be described below with reference to Figures
6
to 10. The commercial distributor may supply such dispenser(s) 40 to customers
as part of the distribution service. The distributor may provide the customer
with
after-sales service directed but not limited to: nature of beverages and
liquid food
products available, use of dispensers, supply of dispensers and payment
options.
Such services may be provided by a computer which supervises management of
product inventory, account payments, maintenance schedules and so on.
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
The commercial distributor will not plan to recover the flexible bags for re-
use, but rather "disposes" of the flexible bags 10 on delivery to the
consumer. In
this way, hygiene problems implicit in prior bottled water distribution
methods that
require re-use of bottles is avoided. Adverse economics due to bottle
recovery,
5 storage and cleaning costs are also avoided. The commercial distributor
disposes of the flexible bags 10 by delivery to the consumer for consumption
of
the beverage or liquid food product without taint or adverse effect due to
recycling
of the delivery container.
Figure 6 shows a dispenser 40, being a refrigerated cooler, having an
10 internal housing 42 in which a filled flexible bag 10 is located. The
flexible bag 10
filled with drinking water, adopts cylindrical shape, when located within
housing
42. Provision of lateral seams 19 and transverse seam 17 of flexible bag 10
assist in achievement of the cylindrical shape. Housing 42 is located on a
stand
44. Housing 42 incorporates a chilling unit 46. The chilling unit 46 may be
constructed following knowledge in the refrigeration art. Housing 42 is
provided
with removable cover 48, the cover being provided with aesthetic design to
enhance customer appeal. Both housing 42 and cover 48 are provided with a slot
or bore 49 through which extends tap 20, as above described, for dispensing
drinking water to a consumer.
Such dispensing of drinking water is assisted by positioning or hanging
flexible bag 10 by handle 15 (see Figure 1 c) by loop 15d placed on a locator
or
other suitable means located on the side wall of housing 42 beneath removable
cover 48. Specifically, the hanging arrangement assists gravity flow of
drinking
water to tap 20. Gravity flow is further assisted by the "funnel" or contour
formed
by the arrangement of seams 16 and 17 when bag 10 is located in housing 42.
The dispenser 40 is not provided with a pump to deliver water through tap 20
to
the consumer. Cost and complexity may thus be avoided.
Figure 7 illustrates a dispenser 140 without a stand 44. In this case, the
dispenser 140 is an ambient dispenser located on a bench top 60.
Figures 8 and 9 provide more detail of the construction of housing 42.
Housing 42 is here illustrated to be of cylindrical section but open, along
much of
its length, along a dispensing segment 43 of the housing 42. A slot or bore 49
is
located at a base 42a of the housing 42 but with a sufficient rim or wall 47
to
CA 02582443 2007-04-05
WO 2005/082715 PCT/AU2005/000281
11
contain a flexible bag 10. Base 42a of housing 42 is angled, at between 15-20
,
to horizontal at the bottom slot or bore 49, to provide a downward gradient
from
the rear wall 42b of housing 42 toward slot or bore 49. This also assists
dispensing of drinking water because the flexible bag 10 Thus, bag 10, when in
dispensing position, may have a sloping "floor" that facilitates drainage of
drinking
water toward slot or bore 49 and tap 20 for dispensing to a consumer. A shield
70, of planar and arcuate construction, and as shown in Figure 10, may be
disposed within rim 47 between tap 20 and tap hole 12 of bag 10 to prevent
wear
or piercing of flexible bag 10 at this point. Aperture 71 of shield 70 is
fitted over
actuator 21 after the tap 20 is fitted to flexible bag 10 thus holding it in
position
proximate the tap 20 protecting the flexible bag 10 in this region. Cuts in
aperture
71 facilitate such positioning. Shields 70 may be of a polymeric or composite
construction. Shields 70 and handles 15 may be supplied in separate bags or
kits, which may also be conveyed in bulk transport container 30, and may be
installed by the distributor. Shield 70 is shown installed in Figure 6 in
dashed
outline.
Base 42a of housing 42 may be arranged relative to a chilling unit 46 such
that base 42a is chilled, thus chilling drinking water within flexible bag 30.
Chilling
unit 46 is only included as required. Refrigeration coils may perform the
chilling
duty. Additional chilling may be required for bags 10 of greater volume.
Once bag 10 is positioned within housing 42 of dispenser 40 and
removable cover 48 is placed into position, the dispenser 40 can be operated
and
tap 20 actuated by actuator 21 to deliver drinking water to the consumer. If
desired, a bag 10 may be pre-chilled in a refrigerator prior to placement in
dispenser housing 42.
Modifications and variations to the distribution methods and devices for
distributing and dispensing beverages and liquid food products in accordance
with the present invention may be apparent to the skilled reader. Such
modifications and variations are deemed within the scope of the present
invention. In particular, any liquid food product or beverage may be
distributed
and dispensed in accordance with the methods and devices of the invention.
