Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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BBA 3.0-001
SYSTEM AND METHOD FOR SUPPLYING EDIBLE SOLIDS
TO A DRINKABLE LIQUID COMPOSITION
s
Applicant claims the benefit under 35 U.S.C. 119(e)
of United States Provisional Application entitled "System and
Method for Supplying Edible Solids to a Drinkable Liquid
Composition", filed on March 13, 1997, Serial No.
The present invention relates in general to a system
and method used in the production of novelty drinks containing
a suspension of edible hydrated hydrocolloids. More
specifically, the present invention relates to a system and
method for separating edible solids from a preservative
solution prior to incorporating the edible solids into a
drinkable liquid composition at one or more processing
stations.
The soft drink industry began more than a century
ago, pioneered by the pharmacy trade which concocted various
drinks for an array of ailments. Famous brands such as Dr.
Pepper~, Coca-Cola~, and Vernors~ trace their histories to
the late 1800's. Over the first half of the 1900's, soft
drinks grew in popularity as an occasional beverage
alternative for all age groups. A core set of flavors - cola,
lemon lime, ginger ale and root beer accounted for nearly all
of the industry's volume. The coming-of-age of the Baby Boom
generation drove per capita soft drink consumption to
unprecedented levels by the early 1970's.
More than any other influence, these same Boomers
brought about changes in the types of soft drinks available,
prompting the introduction of more healthful diet and
caffeine-free products. Bottled waters rode the same wave of
better for you products which carried well into the 1980's.
At the same time, soft drink manufacturers promoted their
sugar-sweetened products aggressively to the teen consumer via
affiliations with entertainment personalities. This marketing
focus was augmented by increased se,rving sizes in both
packaged goods and food service cups.~ By the énd of the
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decade, carbonated soft drink consumption per capita had
passed that of tap water for the first time in history.
During the mid 1980's, more alternative beverages were
introduced, offering the aging soft drink consumer new flavor
choices, formulations with real juice content and all-natural
ingredients. Recognizing the impact of this new era and
volume potential of these soft drink alternatives, the
industry unwittingly christened the so-called New Age beverage
segment.
Originally considered a niche segment of the overall
soft drink market, the New Age beverage category is now
regarded as a separate and distinct product category. By way
of example, New Age beverages include Sports DrinkjIsotonics:
Beverages providing functional benefits in energy build-up,
strength and endurance, or energy restoration; Ready to Drink
Iced Teas: Real-brewed, natural, and flavored varieties of
the chilled leaf liquid first introduced to North America in
1904; Still Water: Natural, non-carbonated, distilled,
purified, spring or well water, typically packaged in clear
plastic bottles; Fruit Juices and Drinks: Comprised of 100%
shelf-stable, non-carbonated juices (fresh or from
concentrate) and juice drinks with less than 100% juice
content; All Natural Sodas: A broad field that includes all
soft drink alternatives positioned as premium, more healthful
sodas, generally colorless, sweetened (both sugar and
aspartame), and formulated with all-natural fruit flavors;
Sparkling Waters: Generally defined as flavor-essenced
mineral waters and sodas with no added sweeteners, either
clear or lightly tinted, and possessing a low (or zero)
calorie content; Sparkling Fruit Juices and Drinks:
Carbonated mineral/filtered water and fruit juice blends,
which may or may not contain flavors, sweeteners, and
preservatives; and Ready-to-Drink Iced Coffee: a beverage
segment still in its infancy and unproven in consumer appeal.
Another category of New Age beverages which have
been recently developed are known as Textural Modified
Beverages. These beverages include disfrete pieces of edible
solids such as real fruit pieces and gel-type hydrated
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hydrocolloids incorporated into drinkable liquid compositions,
such as carbonated and non-carbonated soft drinks, water,
sports drinks, fruit flavored and natural fruit drinks, iced
tea drinks, and the like. These beverages offer the consumer
S a unique visual effect with enhanced taste and texture or
mouth feel. By way of example, there is disclosed in Lewis,
U.S. Patent No. 5,576,039 a Textural Modified Beverage wherein
the edible solids in the form of edible jelly-type substances
of hydrated hydrocolloids, e.g., gellan gum, are suspended in
a drinkable liquid composition.
Once manufactured, the edible solids are often
stored for a period of time prior to being introduced into the
drinkable liquid composition by means of one or more bottle
filling stations in the bottling line. Due to the possibility
of spoilage from bacteria during storage, the edible solids
may include one or more preservatives such as sodium benzoate,
potassium sorbate and mixtures thereof as known from Lewis.
Alternatively, the edible solids can be made with no added
preservatives by being stored in a preservative solution
including one or more preservatives. In the latter case, it
is required that the edible solids be separated from the
preservative solution prior to incorporation into the
drinkable liquid composition.
In either case, the edible solids must be discharged
from their storage container at a rate to meet the demands of
the bottling line. Due to the jelly-type nature of the edible
solids which renders them susceptible to physical damage,
mechanical equipment such as centrifugal pumps and the like
are not suitable for use in transfer systems. As the fill
rate of a typical bottling line can be in the order of 450
bottles per minute, there is the need for a system adaptable
for the continuous or intermittent discharge of storage
containers of these edible solids at a compatible rate, while
at the same time, effectively separating the edible solids
from the preservative solution, all while preventing any
damage to the edible solids.
Accordingly, one object of thle present invention is
to provide a system and method for supplying edible solids to
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a drinkable liquid composition which optimizes the material
handling of the edible solids from its storage container to a
bottling line.
Another object of the present invention is to
provide a system and method for supplying edible solids to a
drinkable liquid composition which is operable for supplying
the edible solids on demand without interruption during the
bottling process.
Another object of the present invention is to
provide a system and method for supplying edible solids to a
drinkable liquid composition which prevents damage to the
edible solids during discharge from their storage container
for transport to the bottling line.
Another object of the present invention is to
provide a system and method for supplying edible solids to a
drinkable liquid composition which accommodates edible solids
provided in a preservative solution within its storage
container.
Another object of the present invention is to
provide a system and method for supplying edible solids to a
drinkable liquid composition in which the edible solids are
separated from the preservative solution prior to being
incorporated into the drinkable liquid composition.
Another object of the present invention is to
provide a system and method for supplying edible solids to
drinkable liquid composition in which the edible solids are
transferred between different elevations using pneumatic
pressure.
In accordance with one embodiment of the present
invention, the system and method enables the filling of
bottles with a drinkable liquid composition and edible solids
without the use of a dual filling method. By dual filling
method it is meant first filling bottles with edible solids at
a first solids bottle filling station, and then, subsequently
filling the bottles with the drinkable liquid composition at a
second liquid bottle filling station. With respect to the
present invention, a concentrated suspension of the edible
solids in the drinkable liquid composition is supplied to a
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single bottle filling station for filling the bottles with
diluent drinkable liquid composition at the desired weight
percentage of edible solids. However, it is to be understood
that, as to be described hereinafter, a dual filling method
S may also be used in accordance with the present invention,
whereby the edible solids separated from the preservative
solution are metered by conventional methods to the solids
bottle filling station.
In either case, the edible solids in a preservative
solution is stored in a 55 gallon fiber container provided
with a polyethylene bag. The container closure head is
removed and replaced with a pneumatic transfer device which
enables pressurizing of the container using an inert gas up to
approximately 14.7 psig. The maximum pressure is limited due
to the container's material construction thereby limiting the
height and distance to which the contents of the container can-
be discharged. By transferring the edible solids using
pneumatic pressure, damage to the edible solids is avoided
which would otherwise occur using mechanical pumps or the
like.
The edible solids along with the preservative
solution are continuously and/or intermittently transferred to
a dewatering device. The dewatering device includes a sloped
screen having perforations which have an effective diameter
smaller than the effective diameter of the edible solids. The
edible solids move, by gravity, across the screen with the
preservative solution passing through the perforations for
discharge. One or more spray nozzles within the dewatering
device are provided for optionally rinsing the edible solids
with an aqueous solution or liquid as to be described, for
example, recycled preservative solution and/or make-up
preservative solution. The drained edible solids are
distributed to one or more mixing vessels. A drinkable liquid
composition is supplied to the mixing vessels for blending
with the edible solids in forming a concentrated suspension.
The resulting suspension is supplied to one or more filling
heads of a bottling line upon demand for dilution with the
drinkable liquid composition using a Lixing tee or venturi
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device, thereby filling the bottles with the desired weight
percentage of edible solids.
In accordance with one embodiment of the present
invention there is described a method of separating edible
solids from a liquid mixture thereof prior to incorporating
the edible solids into a drinkable liquid composition, the
method comprising the steps of providing a source of edible
solids in a liquid, discharging the edible solids and the
liquid from the source, separating the edible solids from the
liquid discharged from the source, and collecting the edible
solids separated from the liquid for incorporation into a
drinkable liquid composition.
In accordance with another embodiment of the present
invention there is described a method of supplying edible
solids to a processing station for suspending the edible
solids in a drinkable liquid composition, the method
comprising the steps of providing a source of edible solids in
a preservative solution therefore at a first elevation,
discharging the edible solids and the preservative solution
from the source by applying other than atmospheric pressure
thereto, passing at a second elevation higher than the first
elevation the discharge edible solids and preservative
solution through a device operative for separating the edible
solids from the preservative solution, supplying the edible
solids to a processing station, and mixing the edible solids
with the drinkable liquid composition at the processing
station.
In accordance with another embodiment of the present
invention there is described a method of providing a
suspension of edible solids in a drinkable liquid composition,
the method comprising providing a source of edible solids in a
preservative solution therefore at a first elevation,
discharging the edible solids and the preservative solution
from the source by applying a positive pressure thereto,
passing at a second elevation higher than the first elevation
the discharge edible solids and the preservative solution over
a support arranged at an incline htaving a plurality of
perforations therein, the perforations having an effective
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size smaller than the effective size of the edible solids for
preventing passage of the edible solids therethrough while
permitting passage of the preservative solution therethrough,
collecting the edible solids separated from the preservative
solution for incorporation into a drinkable liquid
composition, and suspending the edible solids in the drinkable
liquid composition to form a suspension therefrom.
In accordance with another embodiment of the present
invention there is described a system for separating edible
solids from a liquid mixture thereof prior to incorporating
the edible solids into a drinkable liquid composition, the
system comprising means for storing a mixture of edible solids
and a liquid, means for discharging the mixture from the
storage means, and means for separating the edible solids from
the liquid in the mixture prior to incorporating the edible
solids into a drinkable liquid composition.
In accordance with another embodiment of the present
invention there is described a system for supplying edible
solids to a processing station for suspending the edible
solids in a drinkable liquid composition, the system
comprising a container of edible solids in a preservative
solution therefore arranged at a first elevation, a discharge
assembly attachable to the container, the discharge assembly
operative to pressurize the container for discharging the
edible solids and the preservative solution therefrom, a
screening device at a second elevation higher than the first
elevation for separating the edible solids from the
preservative solution discharged from the container, the
screening device including a support having a plurality of
perforations therein, the perforations having an effective
size smaller than the effective size of the edible solids for
preventing passage of the edible solids therethrough while
permitting passage of the preservative solution therethrough,
and means for supplying the edible solids separated from the
preservative solution for incorporation into a drinkable
liquid composition.
In accordance with another em~odiment of the present
invention there is described a system for separating edible
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solids from a liquid mixture thereof prior to incorporating
the edible solids into a drinkable liquid composition, the
system comprising a fiber container storing a mixture of
edible solids in a preservative solution therefore arranged at
a first elevation, the fiber container having a closed bottom
and an openable top, a reinforcing device positionable about
the closed bottom of the fiber container, a transfer head
positionable about the open top of the fiber container
providing access to the interior of the fiber container, means
for connecting the reinforcing device to the transfer head
under a compressive force to create a seal between the
transfer head and the open top of the fiber container, a
source of compressed gas coupled to the transfer head for
maintaining the interior of the fiber container at a
sufficient positive pressure for discharging the edible solids
and the preservative solution therefrom, a screening device
arranged at a second elevation higher than the first elevation
for separating the edible solids from the preservative
solution discharged from the fiber container under the
positive pressure, the screening device including a support
having a plurality of perforations therein, the perforations
having an effective size smaller than the effective size of
the edible solids for preventing passage of the edible solids
therethrough while permitting passage of the preservative
solution therethrough, and means for dispensing the edible
solids discharged from the screening device into a bottle for
suspension with a drinkable liquid composition.
The above description, as well as further objects,
features and advantages of the present invention will be more
fully understood with reference to the following detailed
description of a system and method for supplying edible solids
to a drinkable liquid composition, when taken in conjunction
with the accompanying drawings, wherein:
Fig. 1 is a diagrammatic illustration of a system
for transferring a mixture of edible solids in a preservative
solution from a storage container thereof to a dewatering
station by operation of pneumatic pressu~e;
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Fig. 2 is a diagrammatic illustration of a system
for supplying dewatered edible solids in the form of a
concentrated liquid/solid suspension of drinkable liquid
composition to one or more bottle filling stations;
Fig. 3 is a diagrammatic illustration of a dual
filling system for separately filling metered edible solids
and drinkable liquid composition at separate liquid and solids
bottle filling stations in accordance with another embodiment
of the present invention;
Fig. 4 is a front elevational view of a fiber
container in unassembled relationship with a bottom head
reinforcing device and a top head pneumatic reinforcing
transfer device;
Fig. 5 is a partial cross-sectional view
illustrating the assembled relationship of the reinforcing
device in operative relationship with the bottom head of the
fiber container;
Fig. 6 is a partial cross-sectional view showing the
reinforcing pneumatic transfer device in assembled
relationship with the top head of the fiber container to form
a seal thereat;
Fig. 7 is a diagrammatic illustration of a
dewatering device constructed in accordance with one
embodiment of the present invention; and
Fig. 8 is a diagrammatic illustration of a
dewatering device constructed in accordance with another
embodiment of the present invention.
In describing the preferred embodiments of the
subject matter illustrated in the drawings, specific
terminology will be resorted to for the sake of clarity.
However, the invention is not intended to be limited to the
specific terms so selected, and it is to be understood that
each specific term includes all technical equivalents which
operate in a similar manner to accomplish a similar purpose.
Referring now to the drawings wherein like reference
numerals represent like elements, there is shown in Fig. 1 a
system 100 for supplying dewatered ~edible solids from a
container thereof to a processing sta~ion for incorporation
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into a drinkable liquid composition. The system 100 generally
includes a transfer station 102 and a dewatering station 104.
The transfer station 102 is operative for transferring a
mixture of edible solids and preservative solution from its
storage container to the dewatering station 104. Although the
system 100 has been illustrated as having a single transfer
station 102 and dewatering station 104, it is to be understood
that multiple transfer stations and dewatering stations may be
included within the system as desired.
The transfer station 102 is operative for receiving
a storage drum 106 or other suitable container, such as a
bucket, vessel and the like, for the edible solids supplied as
a mixture with a preservative solution. For example, the
edible solids may be in the nature of jelly-type hydrated
hydrocolloids incorporating water-insoluble colors as
disclosed in Lewis, while the preservative solution may be any
solution containing a preserving agent. By way of example,
the preserving solution may include 12% by weight sugar, 300
PPM sodium benzoate, 50 PPM sodium metabisulfite and the
balance water, adjusted to a pH of about 3. It is
contemplated that sterilized or bacteria free water without a
preserving agent may also be used as the preservative
solution. For illustrative purposes only, the edible solids
content of the mixture may be in the range of about 70-80% by
weight.
The edible solids 168 can be prepared by mixing
water and a suitable gelling agent to form a liquid
composition. The liquid composition can be gelled by heating
until fully hydrated and then cooling the composition.
Alternatively, the liquid composition can be gelled by
reacting the composition with mono- or di-valent ions such as
calcium or sodium ions. The water should be potable and
present in an amount between 80% and 99.8% by weight of the
substance.
Suitable gelling agents include, but are not limited
to, gellan gum, xanthan gum, locust bean gum, pectin,
alginates, carragheenans, starches, ~elatin, and mixtures
thereof. The gelling agent is used in an amount between 0.1%
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and 5% by weight of the substance, preferably between about
0.2% and 1% by weight. In a preferred embodiment, gellan gum
is used in an amount between about 0.1% and 0.5% by weight of
the substance, preferably between about 0.2% and 0.4% by
S weight.
Edible solids 168 prepared using gellan gum are soft
and break up immediately in the mouth. In addition, such
substances are pasteurizable because the substance does not
redissolve on heating. Finally, the texture of the edible
solids 168 can be altered by varying the proportions of other
gelling agents that are used in addition to the gellan gum as
well as other components of the substance. Other water
soluble components that may be included in the edible solids
168 include, for example, sweeteners, acids, ion providers or
buffers, sequestrants, preservatives, water-insoluble colors
and the like. By way of example, orange flavor edible solids
168 include water, sucrose, gellan gum, natural flavor,
extractives of paprika, sodium citrate, xanthan gum, sodium
benzoate, citric acid, potassium metasulphite, vegetable oil
and mono- and di-glycerides. The water insoluble colors as
disclosed in the Lewis Patent are generally provided as a
suspension in water or other suitable liquid media prior to
cooling the liquid composition. Other suitable media include,
but not limited to, propylene glycol, vegetable oil, ethyl
alcohol, and the like. In a preferred embodiment, a
suspension or emulsion having between about 1% and 10% by
weight water-insoluble color is used.
The final amount of color is, of course, determined
by the final color of the edible solids 168 that is desired
and manipulation of the amount of color required to achieve a
desired result can readily be accomplished by one skilled in
the art. In general, the amount of color will range between
about 0.002% and 1% by weight of the edible solids 168
depending on the particular water-insoluble color that is used
and the final color that is desired.
The texture of the edible solids 168 is a function
of the components of the substance andl their proportions and
can be measured using standards of elasticity, brittleness,
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hardness, modulus and cohesiveness. The edible solids 168 can
be produced to have a wide variety of firmness, from a
relatively soft jelly-like consistency to a relatively firm
rubber-like consistency. The firmness of the edible solids
168 can be measured in terms of its strength to resist
crushing. This can be accomplished by placing an edible solid
168 between two plates, and loading the upper plate with lead
shots until the edible solid crushes, i.e., loses its
preformed shape by tending to flatten out. Edible solids 168
having a crush strength of between 60-320 grams of lead shots
are considered generally useful in the present invention.
This covers a range of firmness from a jelly-like consistency
to a relatively firm rubber-like consistency. The preferred
range for the firmness of the edible solids 168 is in the
range from about 85-115 grams of lead shots.
As previously noted, the edible solids to be
incorporated into Textural Modified Beverages may include real
fruit pieces such as whole citrus fruit cells, soft fruit
pieces, e.g., apples, pears, peaches, etc. and tropical fruit
pieces, e.g., mango, papaya, pineapple, etc., as well as
hydrated hydrocolloids as disclosed in Lewis. The transfer
station 102 is particularly suitable for transferring edible
solids formed from hydrated hydrocolloids in the nature of
spherical particles having a diameter of about 4-7 mm.
However, it is to be understood that other sized particles and
shapes may be transferred pursuant to the transfer station
102.
The illustrated storage drum 106 is constructed in
the nature of a conventional 55 gallon container drum having a
separate polyethylene bag functioning as a liner. The storage
drum 106 includes a closed bottom head 108 and a removable top
head (not shown). Fiber containers of this type are known to
possess a certain degree of wall strength when under pressure.
However, these fiber containers are also known to have
relatively poor burst strength at their top and bottom heads.
As to be described hereinafter, the top and bottom heads of
the storage drum 106 are reinforce~ to accommodate the
pressure required to transfer their contents at the transfer
12
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station 102. One commercially available fiber container of
the aforementioned type is available from Greif Container,
Inc. of Delaware, Ohio.
A pneumatic transfer head 112 is attachable to an
open storage drum 106 upon removing its top head to enable
pressurization of the drum. The transfer head 112 for this
purpose includes a shell 110 supporting a compressed gas inlet
114, a pressure gauge 116, a pressure relief valve 117 and a
discharge pipe 118 having an enlarged inlet 120 positionable
adjacent the bottom of the storage drum 106. A source of
compressed gas 122, such as nitrogen, carbon dioxide, filtered
air and the like, is supplied to the transfer head 112 through
a pressure controller 124, a check valve 126 and a shutoff
valve 128.
The dewatering station 104 includes at least one
dewatering device 130 for separating the edible solids from
the preservative solution. The dewatering device 130 includes
a housing 132 having an inlet 134, an edible solids outlet 136
and a preservative solution outlet 138. Extending at a
downward angle within the housing 132 between the inlet 134
and solids outlet 136 is a support 140 having a plurality of
perforations 142. Due to contact with the edible solids, the
support 140 is generally constructed from stainless steel
material having a smooth upper surface which contacts with the
edible solids. The perforations 142 are preferably circular
in nature having an opening size of about 0.5 mm. when the
edible solids are in the form of spherical particles having a
diameter of about 4-7 mm. Also contemplated are other shaped
perforations 142 such as slits, ovals and the like. The
effective diameter of the perforations 142 is therefore
smaller than the effective diameter of the edible solids.
This allows the edible solids to be transported over the
surface of the support 140 by means of gravity while the
preservative solution is drained through the perforations 142.
One or more spray nozzles 144 are positioned within
the housing 132 overlying the support 140. The spray nozzles
144 are connected to a source of an aquelous solution or li~uid
146 through respective shutoff valves 148, 150. A sight glass
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152 is positioned at either end of the housing 132 adjacent
the inlet 134 and edible solids outlet 136. The preservative
solution outlet 138 is connected to a suitable drain 154
through a shutoff valve 156. As to be described hereinafter,
S the solids outlet 136 is connected to a manual three way valve
158 arranged downstream of a branch 160 which is connected to
a shutoff valve 162 and clean-in-place nozzle 164 which
provides for a dual function. The clean-in-place nozzle 164
provides (1) a source of water, steam or cleaning agent to the
dewatering device 130 for cleaning same or (2) a source of
aqueous solution or liquid such as the preservative solution,
a sugar water solution and the like to dislodge accumulated
edible solids as may be required. The clean-in-place nozzle
164, as well as other such nozzles, may be located at other
lS locations within the system 100 as may be desired to
accomplish the dual functions described.
In operation of the system 100 in accordance with
one illustrative embodiment, a 55 gallon fiber storage drum
106 is positioned within the transfer station 102. The
storage drum 106 contains a mixture 166 of edible solids 168
and a preservative solution 170 or sterilized water within a
polyethylene bag. As previously noted, the edible solids are
preferably a hydrated hydrocolloid present in the amount of
70-80% by weight in an aqueous preservative solution present
in the amount of about 20-30% by weight. The preservative
solution contains one or more preservatives such as a mixture
of sodium benzoate and potassium metabisulfite. The edible
solids may be in the form of spheres having a diameter in the
range of 4-7 mm. which facilitates their flow through the
dewatering device 130 during the dewatering process of the
preservative solution.
The top head (not shown) of the storage drum 106 is
removed and replaced with the pneumatic transfer head 112.
This seals the storage drum 106 so as to provide a quasi-
pressure vessel with the inlet 120 of the discharge pipe 118arranged adjacent the bottom of the storage drum 106. The
transfer head 112 is constructed to rei~force the open end of
the storage drum during the pressurized discharge operation.
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Similarly, a reinforcing device 171, see Fig. 4, is positioned
about the bottom head 108 of the storage drum 106 for its
reinforcement. The specific construction of the reinforcing
device and its cooperative association with the pneumatic
transfer head 112 to seal the open end of the storage drum 106
will be described hereinafter with respect to Figs. 4-6.
The interior of the storage drum 106 is pressurized
with a gas, such as inert nitrogen from source 122 under
operation of pressure control valve 124. The storage drum 106
is pressurized, by way of example, in the range of about 5-7
psig, and up to about 14.7 psig depending upon the strength of
the storage drum. The upper limit of pressurizing the storage
drum 106 is based upon the storage drum's composition such as
a fiber drum from Kraft Paper. In the event a steel storage
drum 106 was used, or other pressure vessel, it is
contemplated that higher internal pressures might be used.
The operating pressure is selected to be sufficient to
transfer the mixture 166 from the storage drum 106 to the
dewatering device 130. In this regard, the discharge pipe 118
of the pneumatic transfer head 112 is connected by a transfer
pipe 172 to the inlet 134 of the dewatering device 130. In
the preferred embodiment, the dewatering device 130 is
arranged at a higher elevation than the storage drum 106.
Therefore, the pressure within the storage drum 106 must be
sufficient to convey the mixture 166 to the elevation of the
dewatering device 130, as well as overcoming the frictional
resistance created by the length of the transport pipe 172.
The maximum operational internal pressure of the storage drum
106 thus limits the height of the dewatering device 130 and
the length of the transport pipe 172.
It is also contemplated that a pressure vessel of
any size may be used instead of the storage drum 106. In this
regard, the mixture of edible solids and preservative solution
will be emptied into the pressure vessel at atmospheric
pressure, and the vessel sealed and pressurized to above
atmospheric pressure for feeding same to the dewatering unit
130. In this embodiment, it is possib~e to provide a supply
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of the edible solids multiple times the capacity of a single
storage drum 106.
The mixture 166 received through the inlet 134 of
the dewatering unit 130 is dispensed over the surface of the
support 140 having the plurality of exposed perforations 142.
As previously described, the support 140 is arranged at an
inclined angle to assist transporting of the edible solids 168
thereacross to the solid outlet 136. The particular angle
selected is based, in part, upon the size and geometry of the
edible solids 168, their resistance to flow down an incline,
as well as any tendency of the edible solids to bridge or
accumulate at one location. The particular angle may be
determined by trial and error so as to optimize the natural
passage of the edible solids 168 over the support 140 under
the action of gravity. In this regard, the sight glasses 152
enable viewing of the edible solids 168 at a location adjacent
the inlet 134 and edible solids outlet 136 to determine
visually whether any bridging or backing-up of the edible
solids has occurred preventing their transport through the
dewatering device 130.
In the case of plugging of the dewatering device 130
by the bridging or otherwise accumulation of edible solids 168
therein, an aqueous solution or liquid, such as the
preservative solution, a sugar and water solution or the like
can be injected into the dewatering device through the clean-
in-place nozzle 164 and/or spray nozzles 144 in order to
dislodge the accumulated solids. In addition, the
aforementioned aqueous solution or liquid from source 146 can
be sprayed onto the edible solids 168 using the spray nozzle
144 as the solids are transported across the support 140. The
entering solution or liquid from the spray nozzles 144 will
have two beneficial effects. First, the solution or liquid
can be used to rinse the edible solids 168 of any residual
preservative solution 170. In addition, the added solution or
liquid will have a tendency to lubricate the edible solids 168
to promote their movement by gravity down the support 140 to
the solids outlet 136. The preservati~e solution 170 and/or
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any aqueous solution or liquid passing through the
perforations 142 are discharged to the drain 154.
The edible solids stored with the preservative
solution will absorb by osmotic action a percentage of the
S preserving agents present. The aqueous solution or liquid
brought into contact with the edible solids in the dewatering
unit 130 can be selected so as to leach out a desired
percentage of the absorbed preserving agents. This has the
advantage of lowering the percentage of preservative to levels
which will avoid labeling laws which otherwise would require
their disclosure. By way of example, the aqueous solution can
be a sugar water solution which will have the further benefit
of not removing the sugar present within the composition of
the edible solids, while still achieving the above objectives.
As thus far described, the mixture 166 within the
storage drum 106 is fed to the dewatering device 130 under
operation of pneumatic pressure created by a gas via pressure
control valve 124. By using compressed gas, it is possible to
arrange the transfer station 102 at a lower elevation than the
dewatering station 104. It has been found more convenient to
provide for this arrangement, as this facilitates the movement
of storage drums 106 into and out of the transfer station 102.
In addition, as the dewatered edible solids 168 must be
transported from the dewatering device 130, the arranging of
the dewatering device at a higher elevation enables the use of
gravity to feed the dewatered edible solids 168. In this
regard, it is undesirable to feed the edible solids 168 using
any type of mechanical pump due to the delicate nature of the
edible solids formed typically from hydrated hydrocolloids of
jelly-type consistency.
In an alternative embodiment, it is also
contemplated that the mixture 166 may be transported to the
dewatering device 130 by operation of a vacuum as opposed to
positive pneumatic pressure. In this regard, a source of
vacuum can be connected to the dewatering device 130 to create
a differential pressure between the dewatering device and the
interior of the storage drum 106. Th~s will result in the
withdrawing of the mixture 166 from the storage drum 106 due
CA 02202418 1997-04-11
to the negative pressure differential. It is, however,
preferred to use a positive pressure using an inert gas, as
opposed to a vacuum source. In this regard, it is
contemplated that vacuum may create separation between the
edible solids 168 and the preservative solution 170 within the
storage drum 106.
In still another embodiment, the transfer station
102 may be arranged at an elevation higher than the elevation
of the dewatering station 104. In this embodiment, a non-
pressure vessel may be used into which the mixture 166 fromthe storage drums 106 are emptied. The mixture 166 is
accordingly fed to the dewatering device 130 by gravity as
opposed to being pressure or vacuum assisted. Based on the
above embodiments, it is contemplated that the mixture 166 may
be transported to the dewatering device 130 at the rate of
approximately one pound per second or at any other flow rate
for proper dewatering of the edible solids as may be required
by the design parameters of the system 100 or downstream
bottle filling stations. The feeding operation may be
continuous or intermittent depending upon the demand rate for
the dewatered edible solids 168. In the case of large
demands, particularly where a high capacity bottling line is
used, a plurality of transfer stations 102 may be operatively
connected to one or more dewatering devices 130.
The dewatered edible solids 168 from the dewatering
device 130 are ultimately admixed with a drinkable liquid
composition to form a suspension which is bottled for shipment
to the consumer.
Cut or otherwise formed pieces of the edible solids
168 can be incorporated in a non-drinkable or drinkable liquid
composition having a pH between about 2.5 and 6 in an amount
between about 1% and 10% by weight of the composition,
preferably in an amount between about 5% and 8% by weight.
The liquid composition can be hot or cold, carbonated or non-
carbonated, alcoholic or non-alcoholic, caffeinated or non-
caffeinated, clear or cloudy. Suitable liquid compositions
include, but are not limited to, sod~a, coffee, tea, beer,
milk, mouthwash, and the like. The edible solids 168 remain
18
CA 02202418 1997-04-11
discrete and retain their color during and subsequent to
processing of the liquid composition.
The process of admixing the dewatered edible solids
168 with the drinkable liquid composition and its bottling can
S be achieved in a number of ways. Regardless of the bottling
process being used, it should be kept in mind that the
suspension of the edible solids 168 in the drinkable liquid
composition should preferably be maintained above its
pasteurization temperature during the bottling process as is
known in the conventional food handling industry.
Referring now to Fig. 2, there is illustrated an
edible solids supply system 174 in the nature of a single
filling system in accordance with one embodiment of the
present invention for supplying the dewatered edible solids
168 to one or more bottling stations from the dewatering
device 130 as a concentrated suspension within a drinkable
liquid composition. The system 174 is centered around one or
more enclosed vessels 176, 178 each being provided with
temperature gauges 180 and liquid level gauges 182. The
dewatered edible solids 168 are supplied to the vessels 176,
178 through the three-way valve 158 and respective shutoff
valves 184, 186. A source 188 of the drinkable liquid
composition is supplied to the vessels 176, 178 through
shutoff valves 190, 192, 194. A clean-in-place nozzle 196
provided for injecting water, steam or other cleaning solution
through a shutoff valve 198 can be used, and in the event the
primary shutoff valves 192, 194 leading to the vessels 176,
178 become clogged using, for example, the aforementioned
aqueous solutions and liquids. A source 200 of compressed
gas, for example, nitrogen, carbon dioxide or filtered air is
supplied to each of the vessels 176, 178 at a predetermined
pressure regulated by pressure controller 202 and flow control
valve 204. The gas flow from source 200 may be shut off by
means of corresponding shutoff valves 206, 208 or bypassed by
means of bypass valves 210, 212. Excess pressure within the
vessels 176, 178 may be relieved by pressure relief valves
214, 216. The output from the vessels ~176, 178 is controlled
by control valves 218, 220.
CA 022024l8 l997-04-ll
In operation of the system 174 in accordance with
one embodiment of the present invention, a quantity of the
drinkable liquid composition is supplied to the vessels 176,
178 from source 188 upon opening valves lgo, 192, 194. The
amount of the drinkable liquid composition within the vessels
176, 178 may be monitored by means of the liquid level gauges
182. Subsequently, a quantity of dewatered edible solids 168
is supplied to the vessels 176, 178 through the three-way
valve 158 and valves 184, 186. The amount of drinkable liquid
composition and edible solids within the vessels 176, 178 form
a concentrated liquid/solid suspension 222, the final level of
which is controlled by liquid level gauges 182.
As used within this application, the term suspension
is intended to have the broadest possible meaning with respect
to a mixture of a solid and a liquid. In this regard, the
term suspension is not only intended to include a true
suspension where solids are suspended within the liquid, but
also mixtures wherein the solids have either a higher or lower
density than the liquid so as to either settle or float within
the liquid. In this event, a quasi-suspension can be created
by shaking the bottle so as to form a somewhat homogenous
mixture until separation takes place. Thus, it is intended
that the term suspension encompass the bringing together of a
liquid and solid within the same container.
The amount of drinkable liquid composition is
sufficient to provide flowability of the concentrated
liquid/solid suspension 222 for discharge of same to the
bottling station. By way of one example only, a solids
content of about 50 to 75% by weight within the concentrated
liquid/solid suspension 222 is contemplated.
The vessels 176, 178 supply the concentrated
liquid/solid suspension 222 to a filling line 224 feeding a
bottle filling station 225 having one or more bottle filler
heads 226. The flow of the concentrated liquid/solid
suspension 222 from the vessels 176, 178 iS monitored by a
magnetic flow meter 230 to achieve proper mixing with incoming
drinkable liquid composition from a souFce 300 in the filling
line 224 by computer operation. The computer receives signals
CA 02202418 1997-04-11
from the flow meter 230 to control valve 204 for regulating
the supply of compressed gas to the vessels 176, 178. The
flow rate of the concentrated liquid/solid suspension 222 from
the vessels 176, 178 is therefore regulated by the flow of the
pressurized gas within the vessels, thereby avoiding the use
of mechanical pumps. In a like manner, the flow of the
drinkable liquid composition from source 300 is monitored by a
magnetic flow meter 231 within the filling line 224. The
computer receives signals from the flow meter 231 to control
valve 232 regulating the supply of drinkable liquid
composition. In this manner, the proportions of the
concentrated liquid/solid suspension 222 and drinkable liquid
composition are individually controlled. The mixing of the
concentrated liquid/solid suspension 222 with the drinkable
liquid composition may take place within the filling line 224
at a mixing tee or venturi mixing device generally designated
at 233.
Under operation of a computer control system,
signals detected from flow meters 230, 231 allow the vessel
discharge sequence by first opening control valve 220 and then
control valve 204. The levels of the concentrated
liquid/solid suspension 222 within the vessels 176, 178 are
monitored by the liquid level gauges 182 which may send
signals to the computer control system. When the sensed level
of the concentrated liquid/solid suspension 222 drops to a
predetermined level, the computer control system will advise
the operator that vessel refilling is required. The vessels
176, 178 are refilled with the concentrated liquid/solid
suspension 222 in the manner as previously described. If
desired, the contents of the vessels 176, 178 need not be
concentrated. Rather, the suspension of the edible solids 168
in the drinkable liquid composition in the vessels 176, 178
may be at the desired solids content so that direct bottle
filling may be performed without dilution.
At the filler head 226, drinkable liquid composition
can be mixed directly with the incoming concentrated
liquid/solid suspension 222 as to filli~g the bottles with the
appropriate concentration of edible solids 168. The drinkable
CA 02202418 1997-04-11
liquid composition can be supplied from source 300 or another
source 228 directly to the bottle filling station 225. The
concentrated liquid/solid composition 222 can be supplied from
the filling line 224 or directly from the vessels 176, 178 by
alternative line 229. By way of one illustrative example, ten
ounce bottles can be filled at the bottle filling station 225
at the rate of approximately 450 bottles per minute. The
edible solids 168 within each bottle will be about 5% by
weight. By providing vessels 176, 178 having a capacity of
about 350 gallons of concentrated liquid/solid suspension 222
at about 60% solids, refilling of the vessels would be
required approximately every two hours. Increasing the vessel
capacity to approximately 530 gallons would extend the refill
cycle to approximately three hours. This is based upon a
single filler head 226. In the case of two filler heads 226,
the vessel refill cycle time would be half. The pressure of
the gas within the vessels 176, 178 will be in the order of 3-
10 psig, adjustable to meet the requirements at the filler
system.
The bottling process should be maintained at
elevated temperatures to avoid bacteria and other related
problems associated with food products. The pasteurization
temperature of the drinkable liquid composition is
approximately 195~F. The dewatered edible solids 168 are
supplied to the vessels 176, 178 at room temperature of
approximately 59~F or higher. The drinkable liquid composition
is supplied to the vessels 176, 178 at a temperature of
approximately 200~F. The resulting concentrated liquid/solid
suspension 222 will have a temperature of approximately 135~F.
Under these operating conditions, it might not be required
that the vessels 176, 178 be provided with separate heating
systems. The concentrated liquid/solid suspension 222 is
supplied to the filler head 226 directly via line 229 or to
the filling line 224 where it is mixed with incoming drinkable
liquid suspension from either of sources 228, 300 at a
temperature of approximately 204~F. The resulting temperature
of the suspension will be approximatel~ 195~F. It should be
understood that by changing the composition to include a
CA 02202418 1997-04-11
higher or lower edible solids content, will require a
different thermal analysis than that heretofore described.
The system 174 has been described as providing a
concentrated liquid/solid suspension 222 for feeding a filler
S head 226 set up for dilution with drinkable liquid composition
from source 228 at the bottle filling station 225 or for
feeding the filler head after the concentrated liquid/solid
composition is properly mixed at the desired proportions with
the drinkable liquid composition from source 300. In
accordance with another embodiment as shown diagrammatically
in Fig. 3, there is shown a dual filling system including a
solids filling station 235 and a liquid filling station 237.
The dewatered edible solids 168 from the dewatering device 130
are supplied to the solids filling station 235 where a
metering device 234 meters the solids by weight or volume to a
bottle filling unit 236. During transport of bottles filled
with the edible solids 168 from the solids filling station 235
to a bottle filling unit 240 of the liquid filling station
239, the edible solids may be passed through a heating device
such as a steam tunnel (not shown) for heating the solids to
an elevated temperature if desired. Empty bottles to be
filled are supplied from a source 238. At the bottle filling
unit 236, a metered quantity of the dewatered edible solids
168 are filled into the bottles. The thus filled bottles with
the edible solids are conveyed to the second bottle filling
unit 240. At the second bottle filling unit 240, the bottles
are filled with the drinkable liquid composition from a source
242 thereof.
As previously described, the drinkable liquid
composition from source 242 may be supplied above its
pasteurization temperature. The resulting filled bottles are
capped and may be boxed, stacked and/or palletized for
subsequent storage and/or shipment as generally designated by
element number 244. The filled bottles may pass through a
cooling device such as a cooling tunnel (not shown) before
being packaged and/or palletized. The aforementioned solids
and liquid filling stations 235, 1237 are conventional
equipment known in the food processing industry, such
23
CA 02202418 1997-04-11
equipment being available from, for example, Elmar Industries
of Depew, New York.
Referring now to Figs. 4-6, there will be described
in greater detail the pneumatic transfer head 112 and the
reinforcing device 171 for the bottom head 108 of the storage
drum 106. The reinforcing device 171 is operative for
reinforcing the bottom head 108 and adjacent side wall of the
storage drum 106 during the pressure transfer of the contained
mixture 166 of edible solids and preservative solution
therefrom. As shown, by way of one example, the reinforcing
device 171 is constructed from a cylindrical member. In this
regard, the cylindrical member includes an upstanding wall 246
circumscribing 360~ to provide a receiving cavity 248 sized to
receive the bottom head 108 of the storage drum 106.
Extending radially outward from the upstanding wall 240
opposing each other are a plurality of lugs 250, preferably at
least three, having an opening therein. A configured stepped
bottom wall 252 extends across the bottom of the upstanding
wall 246 to provide a support for the bottom head 108 of the
storage drum 106. The reinforcing device 171 may be fixedly
mounted to the floor at one location within the transfer
station 102 if desired.
As shown in Fig. 5, the bottom head 108 of the
storage drum 106 is received within the receiving cavity 248
in close friction and/or slight compression fit with the
storage drum's side wall. The upstanding wall 246 by being
arranged overlying the side wall of the storage drum 106
prèvents its expansion during the pressurization process when
transferring its contents therefrom. Similarly, the bottom
wall 252 of the reinforcing device 171 is arranged underlying
the bottom head 108 of the storage drum 106 to prevent its
distortion or rupturing during the pressurization process.
The reinforcing device 171 may be easily installed and removed
from one storage drum 106 to another.
The pneumatic transfer head 112 is provided with a
downward depending circular wall 258 providing a receiving
cavity 260 sized to frictionally and/or under slight
compression fit the top head 262 of the!storage drum 106. The
24
CA 02202418 1997-04-11
depending wall 258 prevents expansion of the open end of the
storage drum 106 during the pressurized transfer operation of
its contents. An annular ring 264 extends inwardly from the
interior surface of the depending wall 258 to which there is
attached an annular gasket 266. A plurality of pairs of
closely spaced apart lugs 268, preferably at least three,
providing a narrow opening therebetween are attached extending
radially outward from the downwardly depending wall 258
opposing one another. The narrow openings between the pairs
of lugs 268 are arranged at the same circumferential location
so as to be longitudinally alignable generally with the lugs
250 on the reinforcing device 171.
The storage drum 106 is prepared for discharge of
its contents by initially placing its bottom head 108 into the
lS reinforcing device 171. The cover of the storage drum 106 is
removed and the pneumatic transfer head 112 is positioned
thereover with the gasket 266 resting upon the top edge of the
opening of the storage drum 106. The transfer head 112 may be
attached to a movable arm which allows its manipulation in
both height and location in reference to the open mouth of the
storage drum 106. A seal is created between the gasket 266
and the open mouth of the storage drum 106 by using
comprehensive force created by any suitable device. For
example, a pair of upwardly extending longitudinal tie rods
270 are connectable to the openings within the lugs 250 of the
reinforcing device 171. The other end of the tie rods extend
between the openings created between the pairs of closely
space lugs 268 on the pneumatic transfer head 112. An
enlarged nut 272 may be threadingly received on the threaded
end of the tie rods 270 so as to engage the upper edge of the
lugs 268. By tightening the bolts 272, the gasket 266 is
compressed to create a seal to enable pressurizing of the
interior of the storage drum 106. The storage drum is now
ready for pressurizing to discharge its contents to the
dewatering device 130 in the manner as thus far described. It
is to be understood that the tie rods 270 may be replaced with
any suitable device which will mainta~n a compressive force
upon the gasket 266 to create a seal thereat by the transfer
CA 02202418 1997-04-11
head 112. For example, a hydraulic unit applying a
compressive force on the transfer head 112 may be used.
Referring now to Fig. 7, there is shown in different
detail the construction of the dewatering device 130. The
dewatering device 130 is constructed from a generally
elongated housing 132 of rectangular cross-section as thus far
described with respect to Fig. 1. Further in this regard, a
liquid retention plate 274 is positioned within the interior
of the housing 130 downstream of the preservative solution
outlet 138. The retention plate 274 is operative for
deflecting accumulated preservative solution and/or aqueous
solution or liquid into the outlet 138. Adjacent the solids
outlet 136, the housing 132 includes a downwardly sloping
upper wall 276 which directs the dewatered edible solids 168
emanating from the perforated support 140 to the outlet.
Although not shown, the dewatering device 130 may include
sight glasses 152, a clean-in-place nozzle 164, spray nozzles
144 an the like as previously described with respect to Fig.
1.
Turning now to Fig. 8, there is illustrated a
dewatering device 278 constructed in accordance with another
embodiment of the present invention. The dewatering device
278 includes, by way of example, a cylindrical or rectangular
housing 280 provided with an inlet 282 at the top of the
housing and a solids outlet 284 extending through the bottom
of the housing. A preservative solution outlet 286 is also
positioned within the bottom of the housing 280 connectable to
a waste drain.
Arranged within the interior of the housing 280,
there is provided a cone or conical shaped support 288 having
a plurality of perforations 290. The support 288 may have a
plan configuration to correspond to the interior shape of the
housing 280, for example, circular or rectangular. In any
event, the support 228 is provided with a large central
opening 292 which communicates directly with the solids outlet
284. The support 288 is provided with sloping walls arranged
at an angle which will allow transportl of the edible solids
thereacross during the dewatering ~rocess as thus far
26
CA 02202418 1997-04-11
described with respect to the dewatering device 130. Thus,
the support 288 will have a similar angular orientation as
well as similarly shaped and sized perforations 292.
To facilitate distribution of the incoming mixture
S of edible solids and preservative solution, a cone shaped
deflector plate 294 is positioned overlying the support 288.
The deflector plate 294 has an apex 296 arranged underlying
and spaced from the inlet 282. In this manner, incoming
edible solids and preservative solution will be deflected by
the deflector plate 294 to be distributed circumferentially
about the upper portion of the support 288. In operation, the
dewatering device 278 functions in a similar manner to the
dewatering device 130. The housing 280 may be provided with
sight glasses 152, a clean-in-place nozzle 164, spray nozzles
lS 144 and the like as previously described with respect to the
dewatering device 130.
Although the invention herein has been described
with reference to particular embodiments, it is to be
understood that the embodiments are merely illustrative of the
principles and application of the present invention. It is
therefore to be understood that numerous modifications may be
made to the embodiments and that other arrangements may be
devised without departing from the spirit and scope of the
present invention as defined by the claims.
